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Generac Power Systems 940-2 Portable Generator User Manual

1. A APPR XI MA ELY 8 FOR ATRFLOW UN BUI ENDS UF INVERTER Page 8 11
2. Impact 36 Part 8 SPECIFICATIONS amp CHARTS Impact 36 LP MODEL 0940 0941 TYPE OF ROTOR Permanent Magnet Type Permanent Magnet Type RATED WATTS 3600 3400 RATED VOLTS 115 115 PHASE 1 Phase 1 Phase RATED MAXIMUM LOAD AMPERES 30 0 28 3 RATED FREQUENCY 60 Hz 60 Hz OPERATING SPEED See NOTE 1 Variable Variable ENGINE MODEL GV 220 GV 220 TYPE OF ENGINE Vertical Shaft Vertical Shaft FUEL SYSTEM Gasoline LP Gas COOLING SYSTEM Air Cooled Air Cooled OIL SYSTEM Pressure Pressure OIL PUMP Trochoid Type Trochoid Type AIR CLEANER Paper element w foam pre cleaner Paper element w foam pre cleaner STARTER 12 VDC electric 12 VDC electric IGNITION SYSTEM Solid State Solid State SPARK PLUG Champion RC12YC or equivalent Champion RC12YC or equivalent SPARK PLUG GAP 0 030 inch 0 76mm 0 030 inch 0 76mm NOTE 1 Engine speed will vary between approximately 2400 4000 rpm depending on the load and load voltage NOMINAL RESISTANCES OF GENERATOR WINDINGS Stator Power Phase Windings Stator Timing Winding Lead ACH 0 414 to 0 465 ohm Lead TIM1 orange Lead 0 414 to 0 465 ohm TIM2 97 0 102 to 0 116 ohm Lead SE1 ee 0 414 to 0 465 ohm Stator Battery Charge Winding
3. 2 After engine is thoroughly warmed up shut it down NOTE If the unit is equipped with a gasoline fuel system and GASOHOL was used as a fuel turn off the supply of fuel to the engine and let It run out of gas 3 While engine is still warm from running completely drain the oil Then refill with the recommended oil See Recommended Engine Oil 4 Attach a tag to the engine indicating the viscosity and classifi cation of the oil in the crankcase 5 Remove the spark plug and pour about one 1 ounce 15m1 of clean fresh engine oil into the spark plug threaded opening Crank the engine several times to distribute the oil then install and tighten the spark plug 6 Remove the battery and store it in a cool dry room on a wood en board Never store the battery on any concrete or wood floor 7 Clean and wipe the generator exterior surfaces RETURN TO SERVICE AFTER STORAGE To return the unit to service after storage proceed as follows 1 Verify that the correct oil is in the engine crankcase by check ing the tag on the engine see Recommended Engine Oil If necessary drain oil and refill with the recommended oil 2 Check the battery Fill all battery cells to the proper level with distilled water DO NOT USE TAP WATER IN THE BATTERY If necessary recharge the battery to a 100 percent state of charge or replace it if defective 3 Turn OFF all electrical loads Start the engine at no load and let
4. RED FAN GRN 4 pe REDIBLK s 10 TEMP BLU i 1 SENSE ORG Y SHIELD SHLD gt i 02924589 BLK RED BED s BLK 85 6 B LP ONLY FAN 1 4DC BUS L RED A 2 RTN 1 BLK RED ll e 4 ARTI 4 c ORG 7 dace d i GRN l m7 m 17 nes dita RTN J11 3 ito FAN T m1 K sd M TEMP INVERTER 11 6 b SENSE CONTROL 11 5 SHIELD 7 Ps2 Pst P 55 J10 NEUTRAL CONNECTION BY CUSTOMER CUSTOMER AC CONNECTION GREEN BLACK WHITE LEGEND BCR BATTERY CHARGE RECTIFIER BR1 BRIDGE RECTIFIER BR2 BRIDGE RECTIFIER BR3 BRIDGE RECTIFIER BR4 BRIDGE RECTIFIER CB1 CIRCUIT BREAKER 10A 2 POLE CC CHOKE COIL CH CHOKE HEATER F1 FUSE FP FUEL PUMP ON GASOLINE SHUT OFF VALVE ON L P INV INVERTER BOX HM HOUR METER HTO SWITCH HIGH TEMPERATURE OIL CLOSES ON HIGH TEMPERATURE IC IGNITION COIL IND INDUCTOR ASSEMBLY IM IGNITION MODULE IS IGNITION SENSOR L1 LIGHT RUN OPTIONAL LOP SWITCH LOW OIL PRESSURE CLOSES ON LOW PRESSURE M STEPPER MOTOR THROTTLE CONTROL PCB1 CONTROL CIRCUIT BOARD R1 1 OHM 50 WATTS SC STARTER CONTACTOR IM STARTER MOTOR W1 SWITCH START STOP SW SWITCH FUEL PUMP PRIME SP1 SPARK PLUG LUG BARREL TC TERMINAL CONNECTOR 4 TAB TB TERMINAL BLOCK ENGINE GENERATOR STATO
5. MINIMUM CLEARANCE 1 IN 25 4MM M ENGINE SIDE VIEW Figure 5 Air Inlet in Vehicle Skirt Page 5 2 2 COMPENSATING FOR RESTRICTIONS Such materials as screening louvers or expanded metal can restrict the free flow of air Compensate for this restriction by making the actual air opening pro portionately larger Some materials may offer only a 60 percent free air inlet area Other more efficient materials may provide up to a 90 percent free air inlet area The percentage of free air inlet opening is usually available from the material supplier or manufacturer TO DETERMINE THE ACTUAL AIR INLET OPEN ING SIZE REQUIRED DIVIDE 40 SQUARE INCHES BY THE PERCENTAGE OF FREE AIR INLET AREA FOR THE MATERIAL YOU WILL USE For example If you plan to use screening with an 80 free air inlet area divide 40 by 0 8 which results in 50 square inches Minimum actual size of air inlet opening in this case is 50 square inches An opening that measures 4 inches wide by 12 1 2 inches long provides the required air flow 4 x 12 5 50 square inches INVERTER LOCATION In order for the inverter to work effectively it should be located in a dry well ventilated area Approximately eight inches of space should be allowed at each end of the inverter for adequate ven tilation The sensing harnesses supplied with the inverter have a maximum length of 12 feet If the cables are longer than needed coil the excess near the inv
6. NOTE Use a ballpoint pen or small screwdriver to spin the blades of the inverter cooling fan Momentarily observe a reading of 10 30 mV Page 7 2 18 Section 7 2 ENGINE DC CONTROL SYSTEM TROUBLESHOOTING 5 Momentarily jump Wire 15 located at the fuse holder to Wire 56 located at the Starter Contactor This will initiate cranking of the engine The generator will start but the throttle will need to be controlled manually Hold the throttle at about a half load setting 6 Set a VOM to measure AC Measure the AC voltage at the tim ing winding connector orange and grey wires The voltage should be between 15 and 20 VAC 7 If results are lower there is a possible stator problem Proceed to Test 34 TEST 34 STATOR RESISTANCE VALUES Refer to Part 1 Section 1 4 and 1 5 for test procedures ACTTO AC2 Rn 0 414 to 0 465 ohms Soi ia 0 414 to 0 465 ohms 355 10 HOO ii 0 095 to 108 ohms 510877 222 2 22 2 7 1600 00 0 600000000001 0 095 to 0 108 ohms TIM1 2 0 102 to 0 116 ohms 51 to 0 206 to 0 227 ohms TEST 35 BRIDGE RECTIFIER TEST 1 Disconnect the Red Black Blue Green DC Link wires from either the connection in the control panel or at the inverter Isolate the DC Link wires 2 Turn CB1 to the OFF position 3 Disconnect the 3 pin connector at J4 on the A6060 circuit board 4 Instal paper clips in connector to use as a test point 5 Set a VOM
7. Crankcase Cover Bolts 18 ft Ibs 216 in Ibs Ignition Coil Bolts 5 ft Ibs 60 in Ibs Spark Plug 13 ft Ibs 156 in Ibs Rewind Starter Screws 5 ft Ibs 60 in Ibs Starter Motor Bolts 18 ft Ibs 216 in Ibs Intake Manifold Screws 4 ft lbs 50 in Ibs Carburetor to Intake Manifold 3 3 ft lbs 40 in Ibs Air Cleaner Box to Carburetor 4 ft lbs 50 in Ibs Blower Housing Screws 7 ft Ibs 84 in Ibs Upper and Lower Shroud Screws 4 ft Ibs 48 in Ibs Governor Lever Clamp Bolt 5 8 ft Ibs 70 in Ibs Oil Filter Adapter Bolts 9 ft Ibs 108 in Ibs Low Oil Switch 9 ft Ibs 108 in Ibs Page 8 9 Part 8 SPECIFICATIONS amp CHARTS MAJOR FEATURES AND DIMENSIONS GENERATOR 32 121 438 1724 gt Les 85 04 us 468 m T p L P UNITS SZ Di 1 1 281 111 _ 21 166 Y gt 1 yr REGULATOR 147 p boood d es A n p 1 Fai 1 Sa N LM D 106 OD m 182 7 21 EXHAUST OUTLET Page 8 10 Part 8 SPECIFICATIONS amp CHARTS MAJOR FEATURES AND DIMENSIONS INVERTER a DETAL
8. Figure 3 A Simple Revolving Field Generator Page 1 1 1 Section 1 1 GENERATOR FUNDAMENTALS STATOR STATOR STATOR STATOR N IN ROTOR NE S STATOR 2 __ 90 180 90 180 270 Waveform at 0 amp 180 0000 NO CURRENT Waveform at 90 0 0 0 0 POSITIVE ALTERNATION Waveform at 270 NEGATIVE ALTERNATION Figure 4 Operation of a Simple Generator ALTERNATING CURRENT A simple generator consists of a coil of wires called a Stator and a magnetic field called a Rotor As the Rotor s magnetic field cuts across the Stator coil a voltage is induced into the Stator windings The amount of induced voltage is equal to the strength of the magnetic field See Figure 4 The current alternates according to the position of the Rotor s poles in relation to the position of the Stator At 0 and again at 180 no current flow is produced At 90 of Rotor rotation current flow reaches a maximum positive value Rotor rotation to 270 brings another maximum flow of current However at 270 the current flow has reversed in polarity and now flows in the opposite direction ELECTRICAL UNITS AMPERE The rate of electron flow in a circuit is represented by the AMPERE The ampere is the number of electrons flowing past a given point at a given time One AMPERE is equal to just slightly more than six thou sand million billion electrons per second With alternating curre
9. Page 1 7 4 Section 1 7 SHEET METAL PARTS LIST FOR SHEET METAL GASOLINE UNITS ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 1 1 PLATE DIVIDER 44 3 SPECIAL LOCK WASHER M6 2 32 CRIMPTITE 10 24 x 1 2 45 1 GROUND STRAP UNIT 3 3 5 SEAL RUBBER EXTRUSION 47 1 HOSE 3 8 1 0 x 11 1 2 LONG 4 1 BOX WRAPPER 48 1 BRACKET MUFFLER HANGER 5 31 TAPTITE M5 8 x 10MM 49 2 STREET ELBOW 45 DEG 3 4 6 2 MOUNTING RAILS 50 1 PIPE NIPPLE 3 4 x 2 7 12 M8 LOCK WASHER 51 2 U BOLT W SADDLE 2 NUTS 8 4 M8 1 25 x 35MM HEX HD CAPSCR 53 1 STARTER CONTACTOR GROUND 9 3 HHCS M5 0 8 x 40MM WIRE 11 1 WRAPPER END PANEL 54 1 SEAL WASHER EXHAUST PIPE 12 1 SPARK ARRESTER 55 1 FUEL SOLENOID 12V DC 17 1 DEFLECTOR AIR OUT 57 2 5 16 FLAT WASHER 18 1 ASSEMBLY MUFFLER 58 1 BRACKET L P 19 1 HOUSING LOWER FAN 59 2 CAPSCR HEX HD 1 4 20 x 1 2 20 1 SKIRT CARB BAFFLE 60 1 LP HOOK UP FITTING 21 1 COVER ROCKER COVER 61 2 CUSTOMER MOUNTING BRACKET 22 1 SKIRT SPARK PLUG SIDE 62 4 VIBRATION MOUNT 23 1 PAN BELLY 63 2 EARTHING STRAP 24 1 FRAME 64 8 HEX NUT M8 25 1 GROUND STRAP 65 3 VIBRATION MOUNT 26 1 PLATE BASE COVER 66 1 COVER IGNITION BRACKET 27 1 BARBED EL 90 3 8NPT X 3 8 VS 67 1 1 4 20 TAPTITE 1 1 4 29 5 HEX NUT 1 4 20 68 1 TAG BOLT
10. Figure 1 Remote Panel Plug In Receptacle REMOTE START STOP PANEL A remote mounted Start Stop panel Figure 2 25 is available that allows the user to start and stop the generator engine conveniently from inside the vehicle The remote panel includes a Start Stop switch hourmeter generator run lamp and a wire harness QUARTZH 0 HOURS MOBILE GE Figure 2 Optional Remote Panel Models 004057 and 004184 The remote panels mount a rocker type start stop switch a Generator Run advisory lamp and an hourmeter The hourmeter should be used in conjunc tion with the maintenance operations found in Part I of this manual Model 004057 includes the remote panel and a 10 foot long 4 wire harness Model 004184 includes the remote panel and a 30 foot long 4 wire harness Page 6 6 1 Section 6 6 OPTIONAL REMOTE PANEL Page 6 6 2 7 TROUBLE SHOOTING GENERATOR amp SPEED CONTROL ENGINE DC CONTROL SYSTEM AC TROUBLESHOOTING COMPUTER CONTROLLED VARIABLE SPEED RV GENERATORS Series Impact 36 Plus NOTES PROBLEM POSSIBLE CAUSE Section 7 1 GENERATOR amp SPEED CONTROL SYSTEM TROUBLESHOOTING REFERENCE CHART REMEDY 1 Engine starts accelerates shuts down at 4500 rpm a Carburetor linkage sticking with throttle stuck open b Stepper Motor failed o
11. 3 Remove the two tappets 4 Remove the outer and inner oil pump rotors CRANKSHAFT REMOVAL See Figure 3 To remove the crankshaft proceed as follows 1 The engine flywheel must be removed before the crankshaft can be removed 2 The piston and connecting rod must be removed 3 Remove the crankshaft by pulling it straight out of the crankcase Figure 3 Crankshaft Hemoval Continued Page 2 3 5 Section 2 4 CRANKSHAFT AND CAMSHAFT CAMSHAFT INSPECTION Carefully inspect the entire camshaft for wear nicks damage All areas indicated in Figure 4 should be checked for wear 1 Check spring pins 2 Camshaft gear 3 Compression release parts 4 Main bearing flywheel end 5 Main bearing PTO end 6 Cam lobes Figure 4 Points to Check on Camshaft The following should be measured carefully to check for wear MAIN CAMSHAFT BEARING DIAMETER FLYWHEEL END DESIGN DIAMETER 1 022 1 023 inch 25 96 25 98mm WEAR LIMIT 1 020 inch 25 91mm Minimum MAIN CAMSHAFT BEARING DIAMETER PTO END DESIGN DIAMETER 1 297 1 298 inch 32 96 32 98mm WEAR LIMIT 1 295 inch 32 89mm Minimum CAMSHAFT BEARING BORE IN CRANKCASE DESIGN DIAMETER 1 024 1 025 Inch 26 00 26 03mm WEAR LIMIT 1 026 inch 26 06mm Maximum CAMSHAFT BEARING BORE IN CRANKCASE COVER DESIGN DIAMETER 1 299 1 300 inch 33 00 33 03mm WEAR LIMIT 1 302 inch 33 06mm Maximum CAM LIFT DESIGN LIFT 0 210 0 212 inch 5 34 5 38mm
12. A Starter Motor SM 2 Fuel system components a A Fuel Primer Switch SW2 b Fuel Pump FP CUSTOMER SUPPLIED BATTERY 3 Engine Ignition System Components a Ignition Module IM b Ignition Sensor IS c Ignition Coil IC d Spark Plug SP 4 Engine Protective Devices a Low Oil Pressure Switch LOP b High Oil Temperature Switch HTO 5 An optional Remote Panel continued R BATTERY CHARGE RECTIFIER x CHOKE GASOLINE ONLY CH CHOKE HEATER ECB ENGINE CONTROLLER BOARD AOPTIONAL R RUN LAMP Lor ar PRESS SWIT I 1 OHM SO WATT RESISTOR CONTACTOR STARTER MOTOR SWI START STOP SWITCH SW2 PRIMER SWITCH SP1 SPARK PLUG 1111 el ja 3 3 4 4 YELLD GREEN CONNECTOR o WHITE BROWN REMOTE PANEL COPT IGNAL gt Figure 1 Schematic Engine DC Control System Page 6 1 1 Section 6 1 ENGINE DC CONTROL SYSTEM HOW IT WORKS ENGINE NOT RUNNING 1 Battery output 12VDC is available to the contacts of a starter contactor SC However the contacts are open 2 Battery output is delivered to Terminals J2 5 of the 6060 cir cuit board via Wire 13 a 15 amp fuse and Wire 15 Circuit board action holds this circuit open 3 Battery output is available to a Battery Charge Rectifier BCR via Wire 13 15 amp Fuse F1 Wire 15 a Resistor R1 and Wire 15A PRIMING When the Pri
13. COIL BAD REPLACE A6060 CIRCUIT BOARD TEST 24 CHECK ENGINE pg 7 2 16 ADJUST OR REPAIR CHOKE SYSTEM GOOD CARBURETION REPLACE REPAIR RECONNECT OR REPLACE BAD WIRE S 14 AS NECESSARY TEST 23 CHECK pg 7 2 16 ENGINE RUNS O K NOW Y STOP TESTS TEST 20 TEST IGNITION GOOD MODULE pg 7 2 15 BAD Y REPLACE MODULE REPAIR OR REPLACE ENGINE AS NECESSARY Section 7 2 ENGINE DC CONTROL SYSTEM TROUBLESHOOTING PROBLEM 5 ENGINE STARTS THEN SHUTS DOWN AFTER A FEW SECONDS TURN OFF CB1 SHUTS DOWN RUNS TEST 30 12 WIRE SIGNAL FAIL Pg 7 2 17 TEST 29 CONTINUITY TEST Pg 7 2 17 PASS TEST 32 TEST 29 CONTINUITY TEST Pg 7 2 17 POWER SUPPLY WINDINGS Pg 7 2 18 FAIL PASS DISCONNECT 120 VAC FROM INVERTER TO COACH SHUTS DOWN TEST 26 amp 27 OIL PRESSURE OIL TEMPERATURE Pg 6 5 1 TEST 31 TEST INVERTER Pg 7 2 18 TEST 34 FAIL 2 pa REPLACE STATOR REPLACE INVERTER CHECK FUEL SUPPLY K SHUTS DOWN TURN gt 0 gt 5 RUNS STATOR TEST Pg 7 2 19 CHECK ENGINE PASS OIL LEVEL REPLENISH IF LOW REPLACE A6060 PASS 2 gt CIRCUIT BOARD FAIL REPAIR TEST 34 GOOD STATOR TEST Pg 7 2 19 CHECK FOR COACH AC SIDE DISCONNECT 85
14. CRANK RECHARGE OR REPLACE BATTERY AS REQUIRED YES REPLACE BAD FUSE REPAIR OR REPLACE LOOSE CORRODED OR BAD BATTERY CABLES OR WIRES AS NECESSARY Y NO STOP TEST STS REPLACE TEST 9 CHECK TEST 10 CHECK STARTER WIRE 56 POWER TO BAD 6060 CIRCUIT BOARD STARTER CONTACTOR POWER SUPPLY pg 7 2 12 pg 7 2 13 gt gt REPAIR OR REPLACE BAD WIRE S GOOD GOOD REPLACE A6060 TEST 11 TEST TEST 12 TEST GOOD 3J9 CIRCUIT BOARD STARTER START STOP CONTACTOR SWITCH pg 7 2 13 pg 7 2 13 REPLACE BAD SWITCH REPLACE CONTACTOR P gt OR BAD GROUND WIRE AS NECESSARY PROBLEM 3 ENGINE CRANKS BUT WILL NOT START TEST 13 CHECK TEST 14 CHECK pui ens STILE FUEL SUPPLY GOOD FUEL FILTER en WON T pg 7 2 13 pg 7 2 14 START BAD ENGINE STARTS NOW LOW FUEL LEVEL y en REPLENISH FUEL SUPPLY REPLACE FILTER GO TO TEST 15 ON NEXT PAGE Page 7 2 2 Section 7 2 ENGINE DC CONTROL SYSTEM TROUBLESHOOTING PROBLEM 3 ENGINE CRANKS BUT WILL NOT START CONTINUED TEST 3 CHECK POWER TO TEST 15 CHECK IGNITION SPARK SPARK pg 7 2 14 GOOD TEST 16 CHECK SPARK PLUG GOOD FUEL PUMP pg 7 2 10 pg 72 14 4 _ See NOTE 1 POWER TO PUMP IS GOOD BUT PUMP DOESN T WORK WEAK OR NO SPARK Y Y CLEAN AND REGAP REPLACE OR REPLACE y FUEL PUMP SPARK PLUG NOTE 1 For units with LP gas fuel system check for 12 VDC to the gaseous fuel lockoff solenoid TEST 17 CHECK
15. Connect positive lead to Reading should be Inverter Signal Pin 2 En Com Pin 1 PWM1 2 5 v 2 0 vac Inverter Signal Pin 2 En Com Pin 3 PWM2 2 5 v 2 0 vac Tolerance is large because readings will vary depending on type of meter used Page 7 2 17 Section 7 2 ENGINE DC CONTROL SYSTEM AC TROUBLESHOOTING TEST 31 STATIC TESTS ON INVERTER ASSUMPTION Inverter not connected to generator nverter has been disconnected for at least 5 min utes from running genset to charge TEST PROCEDURE allow capacitors to dis 1 Set a DVOM to DIODE RANGE Measure the 12 position con nector on the inverter according to the chart below Connect the negative and positive test leads as indicated in the chart 2 Set a DVOM to RESISTANCE RANGE Measure the 12 position connector on the inverter according to the chart below Connect the negative and positive test leads as indicated in the chart 49 f 3 Figure 11 12 Position Connector on Inverter 1 Test With DVOM Set At Diode Range Connect negative lead to STATOR TESTS TEST 32 POWER SUPPLY WINDING TEST 1 Disconnect the 12 position cable from the inverter 2 Start the unit with CB1 in the OFF position 3 Set a VOM to measure AC Measure voltage across Pin 6 and Pin 7 The power supply voltage should be approximately 25 30 VAC at approximate
16. ENGINE IGNITION SYSTEM TEST PROCEDURE See Section 6 4 RESULTS 1 Replace Ignition Coil if bad 2 If coil is good go to Test 20 TEST 20 TEST IGNITION MODULE DISCUSSION See Section 6 4 ENGINE IGNITION SYSTEM TEST PROCEDURE Refer to Section 6 4 RESULTS Replace Ignition Module if bad TEST 21 CHECK A6060 CIRCUIT BOARD OUTPUT TO WIRE 14 DISCUSSION If the engine cranks when the Start Stop switch is set to START battery voltage must be available to the A6060 circuit board Section 7 2 ENGINE DC CONTROL SYSTEM TROUBLESHOOTING If the engine cranks but won t start it is possible that a failure in the circuit board has occurred and DC power is not being delivered to the Wire 14 circuit This test will determine if circuit board action will deliver battery voltage to the necessary engine components PROCEDURE Set a VOM to read battery voltage Connect the meter test leads across Pin J2 9 of the A6060 circuit board and Pin J2 6 of the circuit board connector to which common ground Wire 0 connects Crank the engine and the meter should read battery voltage RESULTS 1 If DC voltage was NOT indicated in Test 17 but IS indicated now repair reconnect or replace Wire 14 between board and Ignition Module 2 If no DC voltage in Test 3 but good voltage now replace Wire 14 between board and fuel pump 3 If there is no DC output from the circuit board to Wire 14 replace
17. IGNITION POWER SUPPLY WIRE 14 pg 7 2 14 TEST 18 TEST 19 TEST 20 9999 B Test 2000 TEST IGNITION IGNITION IGNITION SENSOR COIL MODULE NO IGNITION pg 7 2 15 pg 7 2 15 pg 7 2 15 POWER SUPPLY BAD BAD BAD REPLACE REPLACE REPLACE SENSOR COIL MODULE NO DC VOLTAGE TO FUEL PUMP GOOD REPAIR RECONNECT OR REPLACE TEST 21 CHECK BAD WIRE S 14 AS NECESSARY A6060 CIRCUIT BOARD OUTPUT TO WIRE 14 bg 7 2 15 BAD ip REPLACE A6060 CIRCUIT BOARD POWER TO FUEL PUMP IS GOOD AND PUMP OPERATES TEST 22 TEST TEST 23 AUTOMATIC ADJUST OR REPAIR CHECK cHoKe 9999 3 ne NECESSARY pg 7 2 15 pg 7 2 16 ADJUST OR REPAIR BAD 9 CHOKE SYSTEM Page 7 2 3 Section 7 2 ENGINE DC CONTROL SYSTEM AC TROUBLESHOOTING PROBLEM 4 ENGINE STARTS HARD AND RUNS ROUGH TEST 15 CHECK IGNITION SPARK SPARK GOOD pg 7 2 14 ENGINE MISS IS APPARENT TEST 17 CHECK IGNITION POWER SUPPLY WIRE 14 pg 7 2 14 TEST 18 CHECK IGNITION SENSOR pg 7 2 15 NO IGNITION POWER SUPPLY TEST 21 CHECK A6060 CIRCUIT BOARD OUTPUT TO WIRE 14 pg 7 2 15 TEST 22 TEST AUTOMATIC CHOKE pg 7 2 15 Page 7 2 4 REPLACE SENSOR GOOD BAD gt TEST 16 CHECK SPARK PLUG pg 7 2 14 BAD Y CLEAN AND REGAP OR REPLACE SPARK PLUG TEST 19 TEST IGNITION GOOD COIL pg 7 2 15 BAD Y
18. WEAR LIMIT 0 206 inch 5 24mm Minimum CRANKSHAFT INSPECTION CRANKSHAFT PROPER Use a commercial solvent to clean the crankshaft After cleaning inspect the crankshaft as follows Inspect keyways in crankshaft make sure they are not worn or spread Remove burrs from edges of keyway to prevent scratching the bearing Inspect timing gear teeth for chipping or cracking If the timing gear is damaged the crankshaft assem bly must be replaced Page 2 3 6 Inspect the crankpin for damage nicks scratches etc Small nicks and scratches may be polished out using fine emery cloth ALL EMERY RESIDUE MUST BE REMOVED Use a solvent such as kerosene to remove emery residue Carefully measure the outside diameter O D of the crankpin crankshaft journal at flywheel end and crankshaft journal at PTO end Replace the crankshaft if it is worn smaller than the stated limits NOTE DO NOT regrind the crankpin to any small er diameter Undersize connecting rods are NOT available for the GV 220 engines Inspect oil passage Use a length of wire to make sure it is open Inspect threaded ends of crankshaft CRANKPIN OUTSIDE DIAMETER DESIGN DIAMETER 1 180 1 181 inch 29 99 30 01mm WEAR LIMIT 1 179 inch 29 96mm Minimum CRANKSHAFT BEARING JOURNAL FLYWHEEL END DESIGN DIAMETER 1 102 1 103 inch 28 000 28 012mm WEAR LIMIT 1 100 inch 27 95mm Minimum CRANKSHAFT BEARING JOURNAL PTO EN
19. response to signals received from the A6060 circuit board The circuit board senses load voltage establish es the correct engine speed to obtain correct voltage and delivers an output signal to the stepper motor The stepper motor adjusts the engine throttle to change engine speed and establish correct output voltage Figure 1 Carburetor CARBURETOR OPERATION FLOAT OPERATION A hollow plastic float maintains fuel level in the float bowl As fuel is used the float moves downward to move an inlet needle valve off its seat When the needle valve moves off its seat fuel can flow into the bowl As the fuel level rises the float moves upward to force the needle valve against its seat and stop the flow into the bowl Figure 2 Carburetor Sectional View CHOKE POSITION The choke valve is closed to restrict the flow of air into the engine As the engine cranks air pressure in the cylinder is reduced Since the air intake passage is partially blocked by the choke valve fuel is drawn from the main nozzle and from the idle discharge port This creates the very rich fuel mixture required for starting a cold engine IDLE OPERATION The throttle valve is nearly closed to shut off the fuel supply from all ports except the primary idle fuel dis charge port Engine suction then draws fuel only from that port HIGH SPEED OPERATION The throttle valve is wide open This allows a large volume of air to pass through the car
20. 353 0 354 inch 8 969 8 987mm WEAR LIMIT 0 352 inch 8 949mm Minimum OIL FILTER SUPPORT An oil filter support and its gasket are retained to the oil sump by four 4 M6 1 00 bolt A threaded bore is provided in the support for a low oil pressure switch This switch will protect the engine against damaging low oil pressure by shutting the engine down automatically if oil pressure should drop below a pre set low limit A high oil temperature switch is retained to the sup port by two 2 M5 screws and lockwashers This thermal sensor will protect the engine against damag ing high temperature conditions through automatic shutdown 1 Oil Sump 2 M5 Screw 6 Lockwasher 9 Oil Press Switch 3 Lockwasher 7 Screw 10 Oil Pickup 4 Oil Temp Switch Screen 5 Filter Support 8 Pipe Plug Figure 7 Oil Filter Support Page 5 1 3 Section 5 1 ENGINE OIL SYSTEM Page 5 1 4 Section 5 2 ENGINE COOLING SYSTEM It is absolutely essential that an adequate flow of air for cooling ventilating and engine combustion be sup plied to the generator set Without sufficient air flow the engine generator quickly overheats Such over heating can cause serious operating difficulties and may also cause fire and personal injury The installer must make sure that sufficient air is available to the generator for cooling ventilating and combustion The installer must also provide for a path for exhausting the cooling
21. A6060 circuit board uses this signal for speed sensing Page 6 2 2 Section 6 3 ENGINE CRANKING SYSTEM INTRODUCTION COMPONENTS The engine cranking system is shown schematically in Figure 1 below The system consists of the follow ing components A 12 volts Battery A Start Run Stop Switch SW1 A Starter Contactor SC A Starter Motor SM1 A6060 Circuit Board Interconnecting wires OPERATION 1 Holding the Start Run Stop switch SW1 at START connects Wire 17 from the A6060 circuit board to frame ground A6060 circuit board action energizes a crank relay on the board after a three second delay b Closure of the crank relay s contacts delivers 12 VDC to Wire 56 and to a Starter Contactor SC The Starter Contactor SC energizes and its contacts close 2 Closure of the the Starter Contractor SC contacts delivers battery voltage to the Starter Motor SM1 The Motor ener gizes and the engine is cranked A6060 J2 TERMINAL 17 0 0 GROUND F12 7 5 amp Fuse Figure 1 Schematic Cranking Circuit BATTERY RECOMMENDED BATTERY The battery is generally supplied by the customer Recommended is a battery that meets the following requirements Use a 12 VDC automotive type storage battery For prevailing ambient temperatures above 32 F 0 C use a battery rated at 70 amp hours and capable of delivering 360 cold cranking
22. COIL TESTING IGNITION COIL The Ignition Coil is housed in the generator control panel To test the coil proceed as follows 1 Unplug the two halves of the 2 pin connector plug from the Ignition Coil The red and white wires are the primary coil leads 2 To read PRIMARY coil resistance a Set a volt ohm milliammeter VOM to its Rx1 scale and zero the meter Page 6 4 4 b Connect the VOM test leads across the two male pins of the 2 pin connector Primary coil resistance should be about 0 5 to 1 5 ohms 3 To read SECONDARY coil resistance Set the VOM to its Rx10 000 or Rx1 K scale and zero the meter b Unplug the high tension lead from the Spark Plug c Connect one VOM test lead to the white wire connector pin d Connect the other VOM test lead into the Spark Plug lead rubber boot so it contacts the lead s metal terminal end The VOM should read approximately 16 000 17 000 ohms 16 0 17 0 k Ohms Replace the Ignition Coil if defective If the Ignition Coil tested good go to TESTING IGNITION MOD ULE TESTING IGNITION MODULE If a problem was indicated under TESTING FOR SPARK you should have completed the tests under CHECK POWER SUPPLY under CHECK IGNITION SENSOR and under TESTING IGNITION COIL If these components tested good replace the Ignition Module at 7 16 000 17 000 OHMS 0 5 1 5 see Figure 13 Testing Ignition Coil Figure 14 Testin
23. CONTROL SYSTEM NOTES Page 2 Section 3 1 INTRODUCTION TO FUEL SYSTEM GENERAL Recreational vehicle generators equipped with a gasoline fuel system are usually installed so that they share the fuel supply tank with the vehicle engine When this is done the generator Installer must never tee off the vehicle fuel supply line to deliver fuel to the generator When the generator fuel supply line is teed off the vehicle s fuel supply line the more powerful vehicle engine s fuel pump will starve the generator when both are running In addition when the vehicle engine is not running the generator fuel pump will draw all of the gasoline from the vehicle engine line or even from the vehicle engine carburetor This will result in hard starting of the vehicle engine One method of sharing the same fuel supply tank is to Install a special fitting at the tank outlet so that two fuel dip tubes can be fitted In the tank Figure 1 Another method Is to install a new outlet In the tank If the tank has an unused outlet It can be used A second fuel dip tube can be installed in the original tank outlet if the tank outlet is large enough to accom modate two dip tubes The required fittings can be made at a machine shop To install a second fuel out let on the tank means removing the tank to braze or weld a new fitting into place DANGER ATTEMPTING TO WELD OR BRAZE ON A FUEL TANK EMPTY OR NOT IS EXTREMELY DANGEROUS FUEL VAPORS I
24. GENERAL The Stepper Motor consists of an electric motor plus a small gearbox It is shown pictorially and schemati cally in Figure 3 The four 4 motor windings can be tested for a continuity and b shorts to the case It is difficult to perform an operational test of the motor since the amount of motor arm movement is so small TESTING FOR OPEN CONDITION To test the motor windings for an open circuit condi tion proceed as follows 1 Unplug the Stepper Motor connector from its receptacle on the A6060 circuit board 2 Set a volt ohm milliammeter VOM to its Rx1 scale and zero the meter 3 Connect one VOM test probe to the connector pin to which the RED wire attaches This is the DC side of all windings Then connect the other VOM test probe as follows a To the ORANGE wire connector pin Page 3 6 2 Approximately 19 21 ohms should be indicated b To the YELLOW wire connector pin About 19 21 ohms should be read c To the BROWN wire pin for a reading of 19 21 ohms d To the BLACK wire connector pin for a reading of about 19 21 ohms TESTING FOR SHORTED CONDITION 1 Set the VOM to its Rx10 000 or Rx1 K scale and zero the meter 2 Connect one VOM test probe to the RED wire connector pin the other test probe to the Stepper Motor case The meter should read infinity Any reading other than infinity indicates a shorted winding Replace the Stepper Motor if it fails any part of the
25. Solenoid 2 The LP Gas Regulator 3 The carburetor 4 Interconnecting lines and fittings Components that must be added by the generator installer include the following 1 A VAPOR WITHDRAWAL type fuel tank 2 A PRIMARY REGULATOR that will deliver a fuel pressure to the Fuel Lockoff Solenoid of about 11 water column 3 Interconnecting lines and fittings VAPOR WITHDRAWAL LP gas is stored in pressure tanks as a liquid Gaseous fuel system components installed on the generator are designed for vapor withdrawal type systems Such systems use the gas vapors that form above the liquid fuel in the tank Do not attempt to use any liquid withdrawal type tank with the RV generator NOTE Liquid withdrawal type systems use the liquid fuel from the tank The liquid fuel must be vaporized before it reaches the carburetor Fuel vaporization is usually accomplished by porting the liquid fuel through some kind of heating device IMPORTANT CONSIDERATIONS When servicing the gaseous fuel system the following rules apply All lines fittings hoses and clamps must be free of leaks Apply pipe sealant to threads when assem bling threaded connectors to reduce the possibility of leakage Following any service the system must be tested for leaks using APPROVED test methods Optimum gas pressure at the inlet to the fuel lock off solenoid and secondary regulator is 11 inches of water column Do NOT exceed 14 inches water colu
26. WIRE AT CONNECTOR SHUTS DOWN TEST 33 TIMING WINDINGS Pg 7 2 18 FAIL Page 7 2 5 Section 7 2 ENGINE DC CONTROL SYSTEM AC TROUBLESHOOTING PROBLEM 6 GENERATOR DOESN T PULL FULL LOAD CHECK FOR FULL ne GAL ee iaren NUS 4 SECTION 2 2 SECTION 3 4 CHECK FOR LP INLET PRESSURE AT THE REGULATOR UNITS 11 14 H2O WITH A MANOMETER SECTION 4 1 CHECK VALVE LASH 0 001 to 0 003 SECTION 2 2 PROBLEM 7 GENERATOR CIRCUIT BREAKER TRIPS NO AC VOLTAGE DISCONNECT INVERTER START UNIT AND TRIPS AND ISOLATE TURN CB1 ON DC LINK WIRES LOOK FOR SHORT ON DOES NOT TRIP DC LINK WIRES TEST 81 TEST INVERTER FAILS REPLACE pg 7 2 18 FAILS Y REPAIR OR REPLACE TEST 35 BRIDGE RECTIFIER TEST 34 PASS pg 72 19 TEST STATOR pg 7 2 19 FAILS Page 7 2 6 Section 7 2 ENGINE DC CONTROL SYSTEM TROUBLESHOOTING PROBLEM 8 ENGINE SHUTS DOWN UNDER LOAD ENGINE CHECK ENGINE SHUTS DOWN OIL LEVEL REPLENISH IF LOW TEST 26 amp 27 DISCONNECT OIL PRESSURE 85 WIRE RUNS 0 b FAILS OIL TEMPERATURE AT CONNECTOR pg 6 5 1 REPAIR OR REPLACE SHUTS DOWN VERIFY NO SHORT CIRCUIT OF COACH LOADS CAUSING IMMEDIATE SHUTDOWN PROBLEM 9 GENERATOR LOSES AC POWER THEN SHUTS DOWN CHECK INSTALLATION PASS OF INVERTER FOR AIR FLOW NOT ADEQUATE ADEQUATE AIR FLOW FOLLOW LOSES AC POWER INSTALLATION FOLLOWED BY PRO
27. age is delivered to the Fuel Pump to prime the carbu retor With the switch set to OFF battery voltage is deliv ered to the Fuel Pump from the A6060 circuit board during cranking and running via Wire 14 TEST PROCEDURE 1 Disconnect Wires 15 14 and 14A from the switch terminal to prevent interaction 2 Set a VOM to its Rx1 scale and zero the meter 3 Connect the VOM test leads across the Wire 15 terminal and the Wire 14A terminal The meter should read infinity Set the switch to ON or PRIME and the meter should indicate con tinuity 4 Connect the VOM test leads across the Wires 14 and 14 ter minals The meter should read continuity Set the switch to ON or PRIME and the VOM should read infinity RESULTS 1 Replace switch if it fails the test 2 If the switch is good go to Test 7 TEST 7 CHECK WIRE 14A TO FUEL PUMP DISCUSSION If no power was available to the Fuel Pump in Test 3 either the Primer Switch is defective or Wire 14A is open TEST PROCEDURE Inspect Wire 14A between the fuel pump and primer switch for proper connections Check for open condi tion with a VOM RESULTS Repair reconnect or replace Wire 14A as necessary TEST 8 CHECK POWER SUPPLY TO STARTER MOTOR DISCUSSION When the Start Run Stop switch is set to START Wire 17 is connected to ground A6060 circuit board action then delivers a DC voltage to the Starter Contactor coil and the Contactor s
28. air to the exterior of a compartment if so equipped DANGER Never use discharged cooling air for heating or permit such air to enter the vehicle interior This air contains deadly car bon monoxide gas and other poisonous flammable or explosive gases GENERATOR AIR FLOW Engine operation drives cooling fans for the 2 stage cooling air system A pressure fan draws cooling air into the top of generator and into the side of the con trol panel Figure 1 This air flow cools the engine generator and electronic components The second part of cooling system a suction fan draws air that is heated from a hot engine into a collector pan at the base of the unit This heated air although cooler than exhaust muffler is directed across the muffler to cool it The heated air flow is then deflected out the bottom toward the ground Figure 1 Air Flow Through Engine Generator COOLING AIR INLET OPENINGS Ideally you should provide three air inlet openings whether the generator is housed in a conventional compartment or not Two of the openings should be 10 square inches and located as shown in Figure 2 The third opening should provide for a minimum of 40 square inches unrestricted and be located lower on the compartment door NOTE Screening louvers or expanded metal that cover air openings restrict air flow that you must compensate for by making the actual air opening proportionately larger See Compensating for
29. and from the frame 2 POWER PHASE TO TIMING WINDINGS Connect one tester probe to Stator lead AC1 the other test probe to Stator lead TIM1 Apply a voltage of 1000 volts The Tester will indicate breakdown if the windings are shorted together Repeat again with stator lead SL1 3 POWER PHASE TO POWER SUPPLY WINDINGS Connect one tester probe to Stator lead AC1 the other tester probe to Stator lead PS1 Apply 1000 volts If a breakdown Is indicated the windings are shorted together Repeat again with stator lead SL1 Page 1 4 2 4 POWER PHASE TO BATTERY CHARGE WINDINGS Connect one tester probe to Stator Lead AC1 the other probe to Stator lead No 55 Apply 1000 volts If breakdown Is indicated the windings are shorted together Repeat again with stator lead SL1 5 TIMING TO POWER SUPPLY WINDING Connect one tester probe to Stator lead No 1 the other test probe to Stator lead No PS1 Apply 1000 volts If breakdown is indicated the windings are shorted together 6 TIMING TO BATTERY CHARGE WINDING Connect one test probe to Stator lead No TIM1 the other test probe to Stator lead No 55 Apply 1000 volts If breakdown is indicated the windings are shorted together 7 POWER SUPPLY TO BATTERY CHARGE WINDING Connect one test probe to Stator lead No PS1 the other probe to Stator lead No 55 Apply 1000 volts If breakdown is indicated the windings are shorted together RESULTS OF TESTS If testing indicates
30. and runs rough may be caused by a failure in the engine s mechanical system PROCEDURE The first step in checking for an engine problem is to perform a compression check To check engine com pression proceed as follows 1 Remove the spark plug 2 Insert an automotive type compression gauge into the spark plug hole 3 Crank the engine until there is no further in crease in pressure The highest reading obtained is the engine s compression pressure continued Page 7 2 15 Section 7 2 ENGINE DC CONTROL SYSTEM AC TROUBLESHOOTING ENGINE COMPRESSION PRESSURE NOMINAL PRESSURE 60 psi MINIMUM ALLOWABLE 55 psi NOTE Full compression pressure cannot be obtained at cranking speeds due to the action of a compression release mechanism RESULTS If compression is poor look for one or more of the fol lowing possible causes 1 Loose cylinder head bolts 2 Failed cylinder head gasket 3 Burned valves or valve seals 4 Insufficient valve clearance 5 Warped cylinder head 6 Warped valve stem 7 Worn or broken piston ring s 8 Worn or damaged cylinder bore 9 Broken connecting rod TEST 26 TEST OIL PRESSURE SWITCH DISCUSSION See Section 6 5 ENGINE SHUTDOWN FEATURES TEST PROCEDURE See Section 6 5 If necessary connect an external oil pressure gauge to the oil pressure switch port RESULTS 1 Replace oil pressure switch if it is defective or repair Wire 85 circuit as nec
31. circuit is completed through the battery to frame ground and back to the BATTERY CHARGE WINDING via Wire 55 4 Stator timing winding output is delivered to the 6060 circuit board The timing winding output is used to determine engine rpm 5 The stator power supply winding output is delivered to the inverter This is the power supply for operation of the inverter 6 Stator power winding output phase 1 and 2 is delivered to two separate bridge rectifiers where it is rectified to DC This becomes the DC link voltage and is delivered to the inverter STEPPER MOTOR ENGINE CONTROL FUNCTIONS 120 VAC CUSTOMER CONNECTION INVERTER gt BATTERY R1 PHASE 1 STATOR POWER STATOR STATOR STATOR POWER WINDING AC1 AC2 PHASE 2 SUPPLY 511 512 MM WINDING PS1 PS2 TIMING WINDING TM1 TM2 BATTERY CHARGE WINDING 66 77 E PERMANENT ENGINE ROTOR Figure 1 Block Diagram A Generator System Page 1 3 1 Section 1 3 OPERATIONAL ANALYSIS OPERATIONAL DESCRIPTION CONTINUED 7 The A6060 circuit board controls all functions of the generator i e a Engine DC control system b Stepper motor operation 1 If voltage is low the board will signal a STEPPER MOTOR to change engine throt tle setting and increase speed until the desired voltage level is reached 2 If voltage goes high t
32. connects to Pin 1 of the U5 connector b Stator lead TIM2 Gray connects to Pin 2 of the J5 connector 2 Set a VOM to its Rx1 scale and zero the meter 3 Connect one VOM test lead to Pin 1 Lead TIM1 Orange connect the other test lead to Pin 2 Lead TIM2 Gray The meter should Indicate the Stator Timing winding resistance NOMINAL RESISTANCE STATOR TIMING WINDING 0 102 0 116 ohm B To test the Timing winding for a short to ground condition proceed as follows 1 Set the VOM to its Rx10 000 or Rx1 K scale and zero the meter 2 Connect one VOM test lead to Pin 1 of the 2 pin connector Lead TIM1 Orange 3 Connect the other test lead to a clean frame ground on the Stator The meter should read infinity Any reading other than infinity indi cates the Timing winding is shorted to ground SHORT CIRCUIT BETWEEN WINDINGS To test for a short circuit between windings proceed as follows 1 Set a VOM to its Rx10 000 or Rx1K scale and zero the meter 2 Connect one meter test lead to Stator lead PSi Red 3 Connect the remaining test lead to Stator lead AC1 Grey The meter should read infinity Any reading other than infinity indicates a shorted condition and the Stator should be replaced 4 Connect one VOM test lead to Stator lead AC1 the other test lead to Stator lead 77 The VOM should read infinity 5 Connect one VOM test lead to Stator lead AC1 the other test lead to Stat
33. controller This is used for engine speed sensing 6 The system controller sends signals to the inverter for inverter operation 7 The system controller senses load voltage and signals stepper motor operation to achieve required engine speed for correct voltage output WHY VARIABLE SPEED CONTROL Most electrical loads will operate satisfactorily only within a relatively small voltage band In order to pro vide useful voltage at larger load currents it is neces sary to increase engine speed In conventional AC generators some form of voltage regulation is needed to provide correct voltage in the full range of load current This is often accomplished by regulating excitation current to the Rotor field which then regulates the strength of the Rotor s mag netic field The voltage induced into the Stator wind ings is proportional to the strength of the Rotor s mag netic field The Impact Plus computer controlled generator uses a Rotor having a fixed and permanent magnetic field The strength of this magnetic field is fixed and cannot be regulated The output voltage on Impact Plus computer con trolled generators tends to droop with increasing elec trical loads The SYSTEM CONTROLLER maintains a constant AC output voltage by increasing engine and Rotor speed as the load current increases to off set this inherent voltage droop Page 1 1 5 Section 1 1 GENERATOR FUNDAMENTALS Page 1 1 6 Section 1 2 MAJOR GENERAT
34. flow capacity for the generator and other gas appliances in the circuit If the existing primary regulator does not have a suffi cient capacity a replace it with one that has ade quate flow capacity or b install a separate pri mary regulator having at least a 67 cubic feet per hour capacity EXCESS FLOW VALVE Rules established by the National Fire Protection Association NFPA and the Recreation Vehicle Industry Association RVIA require that the LP gas tank be equipped with an excess flow valve This valve and the gaseous fuel lines must be carefully sized so the excess flow valve will close in the event of line breakage Shutoff valves on the fuel supply tank and elsewhere in the system must be fully open when operating the generator The excess flow valve will function proper ly only if all valves are fully open and fuel lines are properly sized LP GAS CARBURETOR LOCKOFF SOLENOID 11 14 inches of water Figure 1 A Typical LP Gas Fuel System Page 4 1 2 Section 4 1 INTRODUCTION TO FUEL SYSTEM GASEOUS CARBURETION Gas at positive pressure is delivered from the fuel lockoff solenoid to the inlet of the regulator about 11 14 inches of water As the engine piston moves downward on its intake stroke air is drawn into the area above the piston through the carburetor venturi A negative pressure is created at the venturi which is proportional to the amount of air that is flowing The negative pressu
35. guide plate In posi tion NOTE Do NOT adjust valve clearance at this time This will be done later Figure 14 Install Rocker Arm amp Pivot Ball stud 7 install the push rod with either end against the tappet a Place the push rod between the guide plate tabs b Place the rocker arm socket onto end of push rod c Alignment is correct when push rod ball rests In the rocker arm socket NOTE The pivot ball stud will be tightened when the valve clearance Is adjusted After valve clear ance has been adjusted the rocker arm cover will be Installed Figure 15 Push Rod Installation ADJUSTING VALVE CLEARANCE When adjusting valve clearance the engine should be at room temperature and the piston should be at top dead center TDC of Its compression stroke both valves closed Section 2 2 VALVE TRAIN VALVE CLEARANCE GV 220 ENGINE INTAKE VALVE 0 001 0 0022 inch 0 03 0 056mm EXHAUST VALVE 0 0018 0 003 inch 0 046 0 07mm Adjust the valve clearance as follows 1 Rotate the crankshaft until the piston is at top dead center TDC of its compression stroke Both valves should be closed 2 Loosen the rocker arm jam nut 3 Use an alien wrench to turn the pivot ball stud while checking the clearance between the rocker arm and the valve stem with a feeler gauge Figure 16 Adjusting Valve Clearance 4 When valve clearance is correct hold the pivot ball stud with the alien wrench while tighten
36. has engine shutdown capability See AUTOMATIC SHUTDOWNS on Page 1 2 5 The 6060 circuit board part of the engine s DC control system also has engine shutdown capability Fortunately neither the generator proper nor the engine DC control system has a large number of parts When a problem is encountered its solution can usually be found after only a few tests PROBLEM 1 PRIMING FUNCTION DOES NOT WORK TEST 3 CHECK POWER TO FUEL O K PUMP pg 7 2 10 TEST 1 CHECK TEST 2 CHECK 7 5 AMP FUSE FUSE gt POWER TO SWITCH pg 7 2 10 GOOD pg 7 2 10 FUSE IS BAD GOOD BUT PUMP ES DOESN T WORK TO SWITCH Y OR LOW POWER REPLACE BAD FUSE TEST 5 TEST FUEL PUMP TEST 4 CHECK pg 3 3 1 BATTERY AND BATTERY CIRCUIT Wires 13 and 15 7 241 pg REPLACE PUMP IF BAD RECHARGE OR REPLACE BATTERY AS REQUIRED NO REPAIR OR REPLACE LOOSE CORRODED OR BAD POWER BATTERY CABLES OR WIRES AS NECESSARY TEST 7 CHECK TEST 6 TEST WIRE 14A SWITCH LI PRIMER SWITCH TO FUEL PUMP GOOD 7 2 11 pg 7 2 12 REPAIR OR REPLACE REPLACE SWITCH DEFECTIVE WIRE 14A IF DEFECTIVE Page 7 2 1 Section 7 2 ENGINE DC CONTROL SYSTEM AC TROUBLESHOOTING PROBLEM 2 ENGINE WILL NOT CRANK TEST 8 CHECK TEST 1 CHECK TEST 4 CHECK POWER SUPPLY POWER 7 5 AMP FUSE FUSE gt BATTERY GOOD ro STARTER MOTOR SUPPLY pg 7 2 10 S000 pg 7 2 11 pg 7 2 12 GOOD FUSE IS BAD BAD LOW OR DOES NO POWER ENGINE Y Y
37. mounted 7 5 amp fuse is connected in series with the 12 VDC power supply to the engine DC control system A blown fuse will prevent engine priming cranking and running TEST PROCEDURE Push in on fuse holder cap and turn it counterclock wise to remove cap and fuse Check the fuse visually If the fuse metal element has melted open replace the fuse If the visual check is uncertain use a VOM to check fuse RESULTS 1 If fuse is good a And if priming function does not work go to Test 2 b And if engine will not crank go to Step 4 2 If fuse is bad replace it Figure 1 7 5 Amp Fuse TEST 2 CHECK POWER TO PRIMER SWITCH DISCUSSION This is a check of the PRIMER SWITCH on the panel When the switch is actuated to its PRIME position fused battery voltage is delivered directly to the elec tric fuel pump on units with gasoline fuel system On units with gaseous fuel system battery voltage is delivered to the fuel lockoff solenoid TEST PROCEDURE Set a VOM to read battery voltage 12 VDC Connect the meter test leads across the Wire 15 terminal of the Primer Switch and frame ground The meter should read battery voltage RESULTS 1 If battery voltage is indicated go to Test 3 2 If battery voltage is NOT indicated go to Test 4 Page 7 2 10 Schematic Pictorial Figure 2 Primer Switch TEST 3 CHECK POWER TO FUEL PUMP DISCUSSION When the rocker type primer switch is held at O
38. switch on the generator panel is actuated to its ON position During engine startup and running conditions when the A6060 circuit board energizes the Wire No 14 circuit Figure 2 Electric Fuel Pump TESTING THE PUMP 1 The pump coil can be tested for an open or shorted condition as follows a Test for Open 1 Disconnect the RED pump wire at its bul let lug 2 Set a VOM to its Rx1 scale and zero the meter 3 Connect one meter test probe to the RED pump wire the other test probe to terminal end of the pump s BLACK lead The VOM should Indicate pump coil resistance FUEL PUMP NOMINAL COIL RESISTANCE ABOUT 29 5 kQ b Test for Shorted condition 1 Disconnect the RED and the BLACK fuel pump leads 2 Set a VOM to its Rx10 000 or Rx1 K scale and zero the meter 3 Connect one VOM test lead to the pump RED lead the other test probe to the pump body The meter should read infinity 2 Pump operation can be tested as follows a Disconnect the fuel line from the outlet side of the fuel pump b Make sure a supply of fuel is available to the Inlet side of the pump c The RED lead from the pump must be connect ed properly into the circuit The pump s BLACK lead must be connected at the pump mounting bolt d Actuate the Fuel Prime switch on the generator panel The pump should operate and should pump fuel from the outlet side NOTE If desired a pressure gauge can be atta
39. that Stator windings are shorted to ground the Stator should be cleaned and dried The insulation resis tance tests should then be repeated If after cleaning and dry ing the Stator again fails the test replace the Stator assembly m If testing indicates that a short between windings exists clean and dry the Stator Then repeat the tests If Stator fails a second test after cleaning and drying replace the Stator assembly CLEANING THE GENERATOR GENERAL If testing indicates that the insulation resistance is below a safe value the winding should be cleaned Proper cleaning can be accomplished only while the generator is disassembled The cleaning method used should be determined by the type of dirt to be removed Be sure to dry the unit after it has been cleaned An electric motor repair shop may be able to assist with cleaning Such shops are often experi enced in special problems sea coast marine wet land applications etc Section 1 4 INSULATION RESISTANCE POWER r l PHASE 1 L POWER PHASE 2 5 POWER SUPPLY PS1 PS2 wv amp TIMING TIM1 TIM2 b BATTERY CHARGE 77 Figure 3 Schematic Stator Windings USING SOLVENTS FOR CLEANING A solvent is generally required when dirt contains oil or grease Only petroleum distillates should be used to clean electrical components Recommended are safety type petroleum solvents having a flash point greater tha
40. the unit for storage see Storage Instructions NOTE DO NOT USE GASOLINE CONTAINING METHANOL NOTE DO NOT MIX OIL WITH THE GASOLINE DANGER GASOLINE IS EXTREMELY FLAM MABLE AND ITS VAPORS ARE EXPLOSIVE DO NOT PERMIT SMOKING OPEN FLAME SPARKS OR ANY SOURCE OF HEAT N THE VICINITY WHILE HANDLING GASOLINE AVOID SPILLAGE OF GASOLINE ON A HOT ENGINE THERE MUST BE NO LEAKAGE OF GASOLINE INTO THE RV GENERATOR COM PARTMENT Page 2 1 2 GASEOUS FUEL SYSTEMS Some RV generator models may be equipped with an LP or natural gas fuel system The use of such gaseous fuels may result in a slight power loss as compared to gasoline However that disadvantage is usually compensated for by the many advantages offered by such fuels Some of these advantages are A low residue content which results in minimum carbon formation in the engine Reduced sludge buildup in the engine oil Reduced burning of valves as compared to gaso line No washdown of the engine cylinder wall dur ing cranking and startup Excellent anti knock qualities A nearly homogenous mixture in the engine cylinder Fuel can be stared for long periods without break down DANGER GASEOUS FUELS ARE HIGHLY VOLATILE AND THEIR VAPORS ARE EXPLO SIVE LP GAS IS HEAVIER THAN AIR AND WILL SETTLE IN LOW AREAS NATURAL GAS IS LIGHTER THAN AIR AND WILL ACCU MULATE IN HIGH AREAS EVEN THE SLIGHT EST SPARK CAN IGNITE THESE FUELS AND CAUSE AN EXPLOSIO
41. thought of as the ability to oppose change in voltage Capacitance exists in a circuit when certain devices are a capable of storing electrical charges as voltage increases and b discharging these stored charges when the voltage decreases Current Leads Voltage Figure 9 Capacitive Reactance WHAT IS AN IMPACT PLUS UNIT The Impact Plus is a computer controlled generator that uses an inverter to create a superior sine wave and maintain a steady frequency These units are dif ferent from conventional generators in that the perfor mance of the engine and AC generator are more accurately matched over a wide range of power needs The Impact Plus computer controlled genera tor provides greater efficiency of both the engine and the generator while maintaining electrical output with in an acceptable voltage range The frequency is con ENGINE BOARD y SYSTEM fO BRIDGE CONTROL INVERTER trolled by the inverter and is maintained at a steady 60 Hz signal throughout the load range Computer controlled generator units have the ability to operate the engine over a wide range of speeds while conventional generators will deliver correct AC frequency and voltage only at a fixed rpm Unlike conventional AC generators the Impact Plus unit can match engine speed to load requirements This provides several advantages as follows Smaller engines can be used to produce mor
42. to the DIODE test range 6 Attach the negative test lead of the VOM to the Red Wire and the positive test lead to the Blue Wire 7 The voltage measured across the Bridge Rectifier should be approximately 1 000 VDC Any voltage reading higher or lower indicates a defective diode assembly Disassemble the Bridge Rectifier and test each diode individually TEST 36 AC POWER WINDING TEST AC1 AC2 SL1 SL2 1 Turn CB1 to the OFF position 2 Set a VOM to measure AC Volts 3 Connect one test lead to the bottom Grey wire AC1 on CB1 Connect the other test lead to the Yellow wire AC2 located on the Bridge Rectifier 4 Start the generator 5 The measured AC voltage reading should be approximately 187 VAC 6 Connect one test lead to the bottom Orange Wire SL1 on CB1 Connect the other test lead to the Brown wire SL2 locat ed on the Bridge Rectifier 7 Start the generator 8 The measured AC voltage reading should be approximately 187 VAC 9 If a lower voltage is measured proceed to Test 34 Page 7 2 19 Section 7 2 ENGINE DC CONTROL SYSTEM AC TROUBLESHOOTING Page 7 2 20 PART 8 SPECIFICATIONS AND CHARTS COMPUTER CONTROLLED VARIABLE SPEED RV GENERATORS Series Impact 36 Plus TITLE General Specifications Nominal Resistances of Generator Windings Electrical Schematic Wiring Diagram Engine Specifications Engine Torque Specifications Major Features and Dimensions NOTES
43. use of common hand tools and any special Generac tools or tools from other suppliers Generac could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and or results of each method We have not under taken any such wide evaluation Therefore anyone who uses a procedure or tool not recommended by Generac must first satisfy himself that neither his nor the products safety will be endangered by the service procedure selected All information illustrations and specifications in this manual are based on the latest product information available at the time of publication When working on these products remember that the electrical system and engine ignition system are capa ble of violent and damaging short circuits or severe electrical shocks If you intend to perform work where electrical terminals could be grounded or touched the battery cables should be disconnected at the battery Any time the intake or exhaust openings of the engine are exposed during service they should be covered to prevent accidental entry of foreign material Entry of such materials will result in extensive damage when the engine Is started During any maintenance procedure replacement fasteners must have the same measurements and strength as the fasteners that were removed Metric bolts and nuts have numbers that indicate their strength Customary bolts use radial lines to ind
44. 0 5mm gap 4 Release the spring clip to lock in the adjustment Figure 4 Set Gap Between Stop Tab and Stop Block Figure 5 Adjusting Throttle Linkage CARBURETOR REMOVAL To remove the carburetor from the engine proceed as follows see Figure 6 next page 1 Disconnect the carburetor fuel inlet line 2 Loosen the clamp and disconnect the carburetor air inlet hose 3 Remove the two M6 1 00 x 90mm screws that retain the carbu retor 4 Remove the carburetor air inlet adapter the air inlet adapter gasket carburetor and carburetor to skirt gasket 5 Remove the sheet metal carburetor skirt 6 Remove two gaskets and the carburetor spacer Page 3 4 3 Section 3 4 CARBURETOR SPACER GASKETS SPACER CARBURETOR SKIRT Page 3 4 4 INLET ADAPTOR HOSE CLAMP q GASKET MOUNTING BOLT Ay TO REGULATOR ____ _ Figure 6 Carburetor Removal Section 3 5 AUTOMATIC CHOKE GENERAL The GV 220 vertical shaft engines are equipped with an automatic choke A choke solenoid is attached to the carburetor choke shaft by means of a choke con trol link Solenoid operation is controlled by the A6060 circuit board The circuit board energizes and de energizes the solenoid cyclically at a rate dependent on ambient temperature during engine cranking only DESCRIPTION See Figure 1 The CHOKE SOLENOID is retained to a CHOKE COVER by two No 4 40 SCREWS LOCK WASHERS and FLATWASHERS The t
45. 1 pas L CBI L J REMOTE PANEL i C OPTIONAL GRN 1 2 1 2 1 2 1 2 AED BLU BRI BR2 BR3 BR4 U pi bs led 4 4 4 4 4 1 2 BLK 0 15 14 d BLU INV II 1 H1 oo X 2 2 M 3 3 4 H 4 J2 gt etreormar GRN 2 90 123456 12 4 Js J5 g SHIELD gt 12 7 SENSE 11 6 gt 10 JI 5 FAN 9 4 lt gt 4 3 8 PWM2 gt 3 2 4 RIN gt 2 1 2 PWM gt 1 1 m PCB1 E Je CJ 3 85 J2 4 17 WHITE 5 6 4 T2 H JA 8 56 sc GRN 9 14 BLK 123 10 1 BLU RED 120V Page 8 2 CUSTOMER AC CONNECTION Part 8 SPECIFICATIONS amp CHARTS WIRING DIAGRAM DRAWING NO 0D4947 B 20F2 4321 5666 CONNECTOR RED o ak RED T z ad CL SHLD iL EEES L 13 men RED bi 1 17086 BRN B 2 GENERATOR CONTROL sul g BLK 4 PEPSI ee T 56 DK BLU 4 GRN Lud Li 15 4 o RED RED CH s RED GRN 14 14 RED o BLK Hp 55 BLK 1 BLK has ii RED tal vin 1 en WHT 5
46. 20 DESIGN DIAMETER 0 709 0 710 inch 18 02 18 08mm WEAR LIMIT 0 711 inch 18 05mm Maximum Page 2 3 2 5 Ring to Groove Side Clearance Clean carbon from piston ring grooves as Install new rings Use a feeler gauge to measure the side clearance between the rings and ring grooves If ring to groove side clearance exceeds the stated limits replace the pis ton RING TO GROOVE SIDE CLEARANCE GV 220 0 0004 0 0014 inch 0 012 0 034mm JST COMPRESSION RING 3RD OL CONTROL RING 2ND COMPRESSION RING Figure 6 Ring to Groove Side Clearance PISTON RINGS GENERAL The following rules pertaining to piston rings must always be complied with Always replace piston rings in sets When removing rings use a ring expander to pre vent breakage Do not spread the rings too far or they will break When installing the piston into the cylinder use a ring compressor This wilt prevent ring breakage and or cylinder damage When installing new rings deglaze the cylinder wall with a commercially available deglazing tool RING DESCRIPTION A piston ring SET consists of a a top compression ring D second compression ring and c an oil ring assembly When installing rings pay close atten tion to the following The OIL RING is a 3 piece assembly which con sists of two oil rails and an oil spacer ring Oil rails have a rounded face and can be installed with either side up The second compression ring h
47. 5 POWER TIMING SUPPLY PS1 e PS2 un TIM2 y BATTERY CHARGE 77 Figure 5 Schematic Stator Windings Page 1 2 3 Section 1 2 MAJOR GENERATOR COMPONENTS Page 1 2 4 Section 1 3 OPERATIONAL ANALYSIS GENERAL Figure 1 below is a block diagram of the Impact Plus computer controlled RV generator The diagram is Intended only for the purpose of illustrating generator operation Refer to the actual wiring diagram for wiring interconnections OPERATIONAL DESCRIPTION 1 The Impact Plus is a computer controlled generator that uses an inverter to create a superior sine wave and maintain a steady frequency of 60 Hz The PERMANENT MAGNET ROTOR is directly coupled to the ENGINE and rotates at the same speed as the engine 2 As the ROTOR turns its magnetic field cuts across a number of STATOR windings to induce a voltage into those windings A voltage is induced into the following STATOR windings a Phase 1 and 2 of the STATOR POWER WIND INGS output leads AC1 AC2 and SL1 SL2 A6060 CIRCUIT BOARD BRIDGE RECTIFIERS pc LINK b The STATOR POWER SUPPLY WINDING with output leads PS1 PS2 c The STATOR TIMING WINDING output leads TIM1 TIM2 d STATOR BATTERY CHARGE WINDING with output leads 55 66 and 77 3 STATOR BATTERY CHARGE WINDING output is delivered to the unit battery via a BATTERY CHARGE RECTIFIER BCR and a 1 OHM 50 WATT RESISTOR The
48. C12YC or equivalent 60 1 1 4 NPT Pipe Plug spark plug with gap set to 0 030 inch 0 76mm NOTE 1 Item 36 Includes valve seats and guides Page 2 1 4 Section 2 2 VALVE TRAIN VALVE TRAIN COMPONENTS Valve train components are listed below and shown in Figure 1 below ITEM QTY DESCRIPTION Tappet Push Rod Rocker Arm Pivot Ball Stud Rocker Arm Jam Nut Push Rod Guide Plate Valve Spring Valve Spring Retainer Valve Spring Washer Exhaust Valve Intake Valve 1 2 3 4 5 6 7 8 9 1 1 O Figure 1 Valve Train Components VALVE COMPONENTS REMOVAL 1 The ROCKER ARM COVER is retained by four M6 1 00 x 12mm screws and lockwashers Remove the four screws and lockwashers then remove the ROCKER ARM COVER and its gasket NOTE Replace the ROCKER ARM COVER GAS KET each time the COVER is removed to ensure proper sealing Figure 2 Removal of Rocker Arm over 2 Loosen the rocker arm jam nuts on the pivot ball studs Then loosen the pivot ball studs Remove the two pivot ball studs the rocker arms and the jam nuts Also remove the push rod guide plate NOTE Keep the Intake valve and exhaust valve parts separated Intake and exhaust parts are Identical However once a wear pattern has been established on these parts their fit will be different Figure 3 Rocker Arm Push Rod amp Guide Plate 3 Remove the push rods 4 Remove the cylin
49. CEDURE CHECK INVERTER NO FAN OPERATION SHUTDOWN FAN FOR OPERATION PEANG 9 OF ENGINE IN 2 MINUTES TEST 30 12 WIRE SIGNAL TEST 29 pg 7 2 17 REPLACE A6060 ef PASS CONTINUITY TEST CIRCUIT BOARD pg 7 2 17 REPAIR OR REPLACE FAIL Page 7 2 7 Section 7 2 ENGINE DC CONTROL SYSTEM AC TROUBLESHOOTING PROBLEM 10 NO AC OUTPUT CB10N OFF TURN ON Y COACH CB TRANSFER ON TEST 29 SWITCH ON OFF FAIL FAIL PASS TURN ON RECONNECT REPAIR REPLACE PA TEST 28 DC LINK VOLTAGE pg 7 2 17 Go to CHECK CB1 on next page TEST 29 INTERNAL TEST 30 12 WIRE SIGNAL pg 7 2 7 2 17 REPLACE A6060 E PASS PASS TEST 31 TEST 32 REPLACE FAIL TESTINVERTER pass POWER SUPPLY INVERTER pg 7 2 18 pg 7 2 18 FAIL TEST 34 REPLACE STATOR KE FAIL STATOR TEST pg 7 2 19 Page 7 2 8 Section 7 2 ENGINE DC CONTROL SYSTEM AC TROUBLESHOOTING PROBLEM 10 NO AC OUTPUT CONTINUED TEST 28 DC LINK VOLTAGE pg 7 2 17 FAIL CHECK CB1 FAIL REPLACE PASS TEST 35 CHECK FAIL REPLACE DIODES BRIDGE RECTIFIER pg 7 2 19 PASS 34 FAIL AC VOLTAGE TO STATOR TEST FAIL gt REPLACE STATOR pg 7 2 19 BRIDGE RECTIFIER pg 7 2 20 Page 7 2 9 Section 7 2 ENGINE DC CONTROL SYSTEM AC TROUBLESHOOTING TEST 1 CHECK 7 5 AMP FUSE DISCUSSION The panel
50. D DESIGN DIAMETER 1 102 1 103 inch 28 000 28 012mm WEAR LIMIT 1 186 inch 27 95mm Minimum 2 Crankshaft gear 3 Oil passage 4 Journal flywheel end 5 Journal PTO end 6 Crankpin 7 Threaded ends Figure 5 Points to Check on Crankshaft Check the crankshaft bearing bore in the crankcase cover If limits are exceeded replace the crankcase cover CRANKSHAFT BEARING BORE IN CRANKCASE COVER DESIGN DIAMETER 1 104 1 105 inch 28 040 28 065mm WEAR LIMIT 1 106 inch 28 092mm Maximum BEARING Figure 6 Bearing Bore in Crankcase Cover COMPRESSION RELEASE MECHANISM A mechanical compression release is provided on the camshaft See Figure 7 A PIN extends over the cam lobe This PIN pushes on the tappet to lift the valve and relieve compression for easier cranking When the engine starts centrifugal force moves the FLY WEIGHT outward against SPRING force The PIN will then drop back and allow the engine to run at full compression Measure the amount of compression release lift at the tappet Figure 8 COMPRESSION RELEASE LIFT FOR GV 220 ENGINE MEASURED AT TAPPET DESIGN LIFT 0 020 0 047 inch 0 50 1 20mm WEAR LIMIT 0 016 inch 0 406mm Minimum CAMSHAFT GEAR SPRING FLYWEIGHT Figure 7 Compression Release Mechanism on Camshaft Section 2 4 CRANKSHAFT AND CAMSHAFT Compression relief lift can aiso be measured at the valve rocker arms using a dial in
51. DC CONTROL SYSTEM TROUBLESHOOTING TEST 11 TEST STARTER CONTACTOR DISCUSSION See Starter Contactor on Page 6 3 2 Replace Starter Contactor if bad TEST 12 TEST START STOP SWITCH DISCUSSION Engine cranking and startup are initiated when the Start Stop switch is held at START to ground Wire 17 Engine shutdown is normally initiated when the Start Stop switch is set to STOP to ground Wire 18 A defective switch can prevent normal startup or nor mal shutdown Pictorial Schematic Figure 7 Start Stop Switch TEST PROCEDURE 1 Carefully inspect Wire 0 Ground between the Start Stop switch and the ground terminal Repair reconnect or replace the wire if necessary 2 Disconnect Wire 17 from its terminal on the Start Stop switch Connect Wire 17 to a clean frame ground The engine should crank 3 Start the engine using the Start Stop switch or by grounding Wire 17 4 Stop the engine by holding the Start Stop switch at STOP If engine will not shut down with switch at STOP ground Wire 18 to stop engine RESULTS 1 If engine cranks when Wire 17 is grounded but won t crank with Start Stop switch replace the Start Stop switch 2 If engine stops when Wire 18 is grounded but will not shut down with Start Stop switch replace the Switch 3 If engine will not crank when Wire 17 is grounded replace the A6060 circuit board 4 If engine will not stop when Wire 18 is grounded re
52. EL LINE 8 LONG 9 2 HHCS M5 0 8 x 40MM 50 1 3 16 CARBURETOR LINE 4 LONG 12 1 SPARK ARRESTOR 51 1 FUEL FILTER 13 1 U BOLT W SADDLE amp NUTS 53 1 STARTER CONTACTOR GROUND 17 1 DEFLECTOR AIR OUT WIRE 18 1 ASSEMBLY MUFFLER 54 1 SEAL WASHER EXHAUST PIPE 19 1 HOUSING LOWER FAN 57 1 PANEL WRAPPER BOX 20 1 SKIRT CARB BAFFLE 59 13 CRIMPTITE 10 24 x 1 2 21 1 COVER ROCKER COVER 60 1 HEX HD CAPSCR M5 0 8 x 12 G8 8 22 1 SKIRT SPARK PLUG SIDE 61 2 CUSTOMER MOUNTING BRACKET 23 1 PAN BELLY 62 4 VIBRATION MOUNT 24 1 FRAME 63 2 EARTHING STRAP 25 1 GROUND STRAP 64 8 HEX NUT M8 26 1 PLATE BASE COVER 65 3 VIBRATION MOUNT 27 1 PUMP FUEL 67 2 TAPTITE 1 4 20 x 1 1 4 28 1 BARBED 90 1 8 x 1 4 68 2 TAG REMOVE BOLT 29 3 HEX NUT 1 4 20 69 6 FLAT WASHER 10 5 30 7 LOCK WASHER 1 4 M6 70 1 BRACKET IGNITION SYSTEM 31 1 CONTACTOR STARTER 71 2 SPACER IGNITION COIL 32 1 BOOT CONTACTOR 72 1 MODULE IGNITION 33 1 SEAL OIL FILTER HOLE 73 1 ASSEMBLY IGNITION COIL 34 1 RETAINER SEAL 74 2 M6 1 0 x 35MM HEX HD CAPSCREW 35 4 M8 FLAT WASHER 75 4 M6 1 0 HEX NUT 36 1 1 4 FUEL LINE 4 LONG 76 2 M5 0 8 x 12MM PPHMS 37 5 1 4 HOSE CLAMP 77 2 5 0 8 HEX NUT 38 1 SNAP BUSHING 78 4 LOCK WASHER M5 39 4 SPECIAL LOCK WASHER M5 79 1 RUBBER U CHANNEL 0 5 FT 40 2 8 HEX NUT 80 1 CRIMPTITE 10 24 x 3 8 41 2 8 LOCK WASHER 81 1 COVER IGNITION SYSTEM Page 1 7 3 Section 1 7 SHEET METAL EXPLODED VIEW OF SHEET METAL LP UNITS
53. ERVICE NOTE Proper lapping of valves and valve seats will remove grinding marks and ensure a good seal between the valve and its seat Be sure to clean lapping compound from the valve seats and faces VALVE MARGIN GV 220 DESIGN MARGIN 0 034 0 04 inch 0 87 1 13mm WEAR LIMIT 0 020 inch 0 50mm Maximum INTAKE VALVE STEM DIAMETER GV 220 DESIGN DIAMETER 0 274 0 275 inch 6 965 0 980mm WEAR LIMIT 0 273 Inch 6 934mm Minimum EXHAUST VALVE STEM DIAMETER GV 220 DESIGN DIAMETER 0 273 0 274 inch 6 945 6 960mm WEAR LIMIT 0 272 inch 6 909mm Minimum NOTE Design sizes and wear limits of valve train components can also be found in Part 9 of this Manual SPECIFICATIONS amp CHARTS VALVE SEATS Valve seats are NOT replaceable If burned or pitted seats can be reground Grind seats at a 45 angle and to a width of 0 039 inch 1 Mm Figure 7 Valve Seat VALVE SEAT WIDTH GV 220 DESIGN WIDTH 0 034 0 044 inch 0 87 1 13mm WEAR LIMIT 0 064 inch 1 63mm Maximum VALVE GUIDES Valve guides are permanently installed in the cylinder head and cannot be replaced If the guides become worn beyond the wear limit they can be reamed to accommodate a 0 020 inch 0 50mm oversize valve stem Use a straight shank hand reamer or a low speed drill press to ream valve guides VALVE GUIDES GV 220 DESIGN DIAMETER 0 237 0 2364 inch 6 02 6 005mm WEAR LIMIT 0 238 inch 6 045mm
54. FT SLEEVE BEARING DESIGN DIAMETER WHERE APPLICABLE 1 104 1 106 inch 28 044 28 099mm GOVERNOR ARM BORE DESIGN DIAMETER 0 239 0 240 inch 6 07 6 10mm CAMSHAFT BEARING DESIGN DIAMETER 1 024 1 025 inch 26 00 26 03mm GOVERNOR ARM DIAMETER DESIGN DIAMETER MODEL 0 235 0 237 inch 5 97 6 03mm Later model small frame GN engines have no crankshaft sleeve bearing CRANKCASE COVER ASSEMBLY CRANKSHAFT BEARING BORE DESIGN DIAMETER 1 104 1 105 inch 28 040 28 065mm CAMSHAFT BEARING BORE DESIGN DIAMETER 1 299 1 300 inch 33 00 33 03mm GOVERNOR GEAR SHAFT DIAMETER 0 236 0 237 inch 6 004 6 012 OIL PUMP INNER ROTOR SHAFT DIAMETER DESIGN DIAMETER 0 353 0 354 inch 8 969 8 987mm Page 8 5 Part 8 SPECIFICATIONS amp CHARTS MODEL CRANKSHAFT GV 220 CRANKPIN DIAMETER DESIGN DIAMETER 1 180 1 181 inch 29 99 30 01mm CRANKSHAFT MAIN BEARING FLYWHEEL END DESIGN DIAMETER 1 102 1 103 inch 28 000 28 012mm CRANKSHAFT MAIN BEARING PTO END DESIGN DIAMETER MODEL 1 102 1 103 inch 28 000 28 012mm CONNECTING ROD ASSEMBLV LARGE END INSIDE DIAMETER DESIGN DIAMETER 1 183 1 184 inch 30 06 30 07mm SMALL END INSIDE DIAMETER DESIGN DIAMETER 2 196 2 213 inch 55 8 56 2mm PISTON PIN LENGTH DESIGN DIAMETER 1 102 1 103 inch 28 000 28 012mm PISTON PIN OUTSIDE DIA
55. GINE LONG BLOCK ITEM DESCRIPTION ITEM DESCRIPTION 1 1 Connecting Rod 31 2 valve Spring 2 1 Piston Pin 32 1 Dowel Pin 3 1 Piston Ring Set STD 33 1 Inner Oil Pump Rotor 4 2 1 4 Pipe Plug 34 2 Connecting Rod Bolt 5 1 Breather Cover 36 1 Cylinder Head see NOTE 1 6 1 Piston 37 1 Exhaust Valve 7 2 Piston Pin Retainer 38 1 Intake Valve 8 1 Crankshaft amp Gear Assembly 39 2 Push Rod 10 1 Oil Breather Separator 40 2 Tappet 11 1 Crankcase Assembly 41 1 Oil Pickup Screen 12 1 Sleeve Bearing 42 1 Rocker Cover Gasket 13 2 Crankshaft Oil Seal 43 2 Pivot Ball Stud 14 1 Breather Baffle Cup 44 2 Rocker Arm 15 4 M6 Screw 45 2 Rocker Arm Nut 16 4 Lockwasher 46 1 Push Rod Guide Plate 17 3 Dowel Sleeve 47 5 Head Bolt 18 1 Camshaft Assembly 48 1 Rocker Cover 19 1 Crank Case Flange Gasket 49 2 Breather Gasket 21 1 Cylinder Head Gasket 50 2 Bolt 22 1 Oil Pressure Spring Retainer 51 1 Outer Oil Pump Rotor 23 1 Oil Pressure Spring 52 1 Oil Sump Assembly 24 1 Oil Pressure Relief Valve Ball 53 2 Valve Spring Wear Washer 25 1 Thread Forming Bolt 54 1 Intake Valve Seal 26 4 M6 Screw amp Lockwasher 55 1 Oil Temperature Switch 27 1 Oil Filter Adapter 56 2 Screw 28 6 M8 1 25 Capscrew 57 2 M3 Lockwasher 29 1 Oil Pressure Switch 58 1 Spark Plug see NOTE 2 30 2 Valve Spring Retainer 59 1 Oil Filter Adapter Gasket NOTE 2 Use a Champion R
56. METER DESIGN DIAMETER MODEL PISTON 0 708 0 709 inch 17 989 18 000mm PISTON MAJOR DIAMETER DESIGN DIAMETER 2 753 2 754 inch 69 939 69 959mm PISTON MINOR DIAMETER DESIGN DIAMETER Page 8 6 2 747 2 748 inch 69 789 69 809mm Part 8 SPECIFICATIONS amp CHARTS MODEL PISTON CONTINUED GV 220 WRIST PIN BORE DIAMETER DESIGN DIAMETER 0 708 0 709 inch 18 000 18 011mm TOP RING GROOVE WIDTH DESIGN WIDTH 0 059 0 061 inch 1 52 1 54mm SECOND RING GROOVE WIDTH DESIGN WIDTH 0 059 0 061 inch 1 52 1 54mm OIL CONTROL RING GROOVE WIDTH DESIGN WIDTH 0 118 0 119 inch 3 01 3 03mm TOP RING WIDTH DESIGN WIDTH 0 057 0 059 inch 1 47 1 49mm TOP RING END GAP DESIGN END GAP 0 005 0 016 inch 0 15 0 40mm SECOND RING WIDTH DESIGN WIDTH 0 057 0 059 inch 1 465 1 490mm SECOND RING END GAP DESIGN END GAP 0 006 0 016 inch 0 15 0 40mm OIL CONTROL RING WIDTH DESIGN WIDTH 0 111 0 118 inch 2 825 3 003mm OIL CONTROL RING END GAP DESIGN END GAP 0 015 0 055 inch 0 38 1 40mm NOTE 1 Measure end gap with ring pushed down in cylinder to depth of 2 75 inches Page 8 7 Part 8 SPECIFICATIONS amp CHARTS MODEL CAMSHAFT ASSEMBLY MAIN CAMSHAFT BEARING DIAMETER FLYWHEEL END DESIGN DIAMETER 1 022 1 023 inch 25 96 25 98mm MAIN CAMSHAFT BEARING DIA
57. METER PTO END DESIGN DIAMETER 1 297 1 298 inch 32 96 32 98mm CAM LIFT DESIGN LIFT 0 210 0 212 inch 5 34 5 38mm BASE CIRCLE DIAMETER OF CAM DESIGN DIAMETER 0 978 0 990 inch 24 85 25 15mm COMPRESSION RELEASE LIFT MEASURED AT TAPPET DESIGN LIFT MODEL OIL PUMP 0 027 0 055 inch 0 70 1 40mm GV 220 PUMP TIP CLEARANCE DESIGN CLEARANCE 0 0000 0 0010 inch 0 000 0 025mm INNER ROTOR BORE DESIGN BORE 0 354 0 355 inch 9 000 9 019mm INNER ROTOR THICKNESS DESIGN THICKNESS 0 312 0 315 inch 7 95 8 00mm OUTER ROTOR OUTSIDE DIAMETER DESIGN DIAMETER 1 296 1 297 inch 32 92 32 95mm OUTER ROTOR THICKNESS DESIGN THICKNESS NOTE 2 Measure pump tip clearance on shaft in crankcase cover Page 8 8 0 314 0 316 inch 8 000 8 025mm MODEL OIL PUMP CONTINUED Part 8 SPECIFICATIONS amp CHARTS GV 220 OIL PRESSURE RELIEF VALVE SPRING Force required to compress spring to 1 035 inch 26 3mm MODEL COMPRESSION PRESSURE 0 85 0 95 pounds 0 39 0 43kg GV 220 WHILE CRANKING COLD ENGINE MODEL TORQUE SPECIFICATIONS 60 psi min GV 220 Rocker Cover Screws 4 ft Ibs 48 in Ibs Rocker Arm Jam Nut 14 5 ft Ibs 174 in Ibs Cylinder Head Bolts 22 ft Ibs 264 in Ibs Connecting Rod Bolts 10 ft Ibs 120 in Ibs Flywheel Nut 75 ft lbs 900 in Ibs
58. Manual Part 009057 SERVICE MANUAL SERIES IMPACT 36 PLUS Il Models 940 2 amp 941 2 GENERAC POVVER SYSTEMS INC Box 297 Whitewater WI 53190 Phone 262 473 5514 Fax 262 472 6505 Printed in U S A Revision A 07 15 03 Throughout this publication DANGER and CAUTIONI blocks are used to alert the mechanic to special instructions concerning a particular service or operation that might be hazardous if performed incorrectly or carelessly PAY CLOSE ATTENTION TO THEM DANGER UNDER THIS HEADING WILL BE FOUND SPECIAL INSTRUCTIONS WHICH IF NOT COM PLIED WITH COULD RESULT IN PERSONAL INJURY OR DEATH CAUTION Under this heading will be found special instructions which if not complied with could result in damage to equipment and or property These Safety Alerts alone cannot eliminate the hazards that they signal Strict compliance with these spe cial Instructions plus common sense are major accident prevention measures NOTICE TO USERS OF THIS MANUAL This SERVICE MANUAL has been written and published by Generac to aid our dealers mechanics and com pany service personnel when servicing the products described herein It is assumed that these personnel are familiar with the servicing procedures for these products or like or similar products manufactured and marketed by Generac That they have been trained in the recommended servicing procedures for these products including the
59. Maximum Section 2 2 VALVE TRAIN NOTE After the valve guides have been over sized be sure to recut the valve seats so they will align with the guides Figure 10 Valve Spring VALVE GUIDES VALVE SPRING FREE LENGTH GV 220 2 0741inch 52 69mm Figure 8 Valve Guides FORCE REQUIRED TO COMPRESS SPRING TO 1 39 INCH 35 2MM VALVE TAPPETS GV 220 19 8 21 81lbs 9 0 9 9kg Valve tappets can be removed during removal of the engine camshaft Intake and exhaust valve tappets VALVE COMPONENTS INSTALLATION are identical However once a wear pattern has been established the two tappets should not be After the valve train parts have been inspected and Interchanged necessary serviced install them as follows 1 Lubricate the valve stems and the valve guides with engine oil 2 Install the intake and exhaust valves through their respective valve guides In the cylinder head a The exhaust valve has the smaller head with a diameter of 1 053 inches 26 75mm b The intake valve has the larger head having a diameter of 1 171 inches 29 75mm c Valve seat sizes in the cylinder head will match their respective head sizes NOTE The exhaust valve stem Is also smaller than that of the Intake valve Figure 10 Valve Tappet VALVE SPRINGS Inspect the valve springs Measure the spring free length Also check the amount of force req
60. N position fused battery voltage is delivered to the elec tric fuel pump The pump should then turn on and prime the carburetor During cranking and startup the A6060 circuit board will deliver battery voltage to the Wire 14 circuit and to the Fuel Pump The pump should turn on and run Figure 3 Fuel Pump TEST PROCEDURE Locate the red Wire 14A that connects to the fuel pump wiring connector connects the wires near the pump Separate the wire then check for DC power as follows 1 Set VOM to read battery voltage 2 Connect the VOM test leads across the Wire 14A from the Primer Switch and frame ground 3 Hold the Primer Switch at ON Prime Meter should read bat tery voltage 4 Hold the panel Start Run Stop switch at START The meter should read battery voltage Section 7 2 ENGINE DC CONTROL SYSTEM AC TROUBLESHOOTING RESULTS 1 If unit is being tested because the priming function doesn t work a f battery voltage is good but the pump doesn t work go to Test 5 b f battery voltage is NOT indicated go to Test 6 2 If engine cranks but will not start a f battery voltage is good but the pump doesn t work go to Test 5 b If DC power to pump is good and pump works go to Test 22 TEST 4 CHECK BATTERY BATTERY CIRCUIT DISCUSSION The battery circuit includes the red battery cable that extends from the units 12 volt battery to the Starter Contactor The circuit also include
61. N THE TANK WILL RESULT IN AN EXPLOSION The generator s fuel dip tube in the tank should be shorter than the vehicle engine s dip tube This will prevent the generator from consuming the entire fuel supply DANGER THE FUEL SYSTEM DESIGNED AND INSTALLED BY THE GENERATOR MAN UFACTURER IS IN STRICT COMPLIANCE WITH STANDARDS ESTABLISHED BY THE RECREATIONAL VEHICLE INDUSTRY ASSO CIATION RVIA NOTHING MUST BE DONE DURING MAINTENANCE THAT WILL RENDER THE SYSTEM IN NON COMPLIANCE WITH THOSE STANDARDS DANGER THERE MUST BE NO LEAKAGE OF GASOLINE OR GASOLINE VAPORS INTO THE VEHICLE THE GENERATOR COMPARTMENT MUST BE VAPOR TIGHT TO PREVENT ENTRY OF FUEL VAPORS OR FUMES INTO THE VEHICLE THE GENERATOR S VENTILA TION SYSTEM MUST PROVIDE A FLOW OF AIR THAT WILL EXPEL ANY FUEL VAPOR ACCUMULATIONS RECOMMENDED FUEL Use a high quality UNLEADED gasoline Leaded REGULAR grade gasoline is an acceptable substi tute Do NOT use any fuel containing alcohol such as gasohol If gasoline containing alcohol is used it must not contain more than 10 ethanol and it must be removed from the generator fuel system during storage do NOT use fuel containing methanol If any fuel containing alcohol Is used the system must be inspected more frequently for leakage and other abnormalities FUEL LINE TO PROPULSION ENGINE FUEL LINE TO PIPE NIPPLE FUEL TANK ANTI SIPHON HOLE Figure 1 Sharing a Fuel Supply Tank EVAPORATION CONT
62. N THE USE OF LEAK DETECTORS IS RECOMMENDED WHEN GASEOUS FUELS ARE USED ALL CODES STANDARDS AND REGULATIONS PERTAIN ING TO THE INSTALLATION AND USE OF GASEOUS FUELS MUST BE COMPLIED WITH RECOMMENDED ENGINE OIL Use a clean high quality detergent oil that is classi fied For Service SC SD SE SF or SG Use no special additives with the oil During summer months above 32 F or 0 C use SAE 30 oil SAE 10W 30 oil is an acceptable sub stitute During winter months below 32 F or 0 C use SAE 5W 20 or 5W 30 oil DO NOT USE SAE 10W 40 OIL Section 2 1 GENERAL INFORMATION Engine crankcase oil capacity without oil filter change is about 29 fluid ounces 850m Engine crankcase oil capacity with oil filter change is about 1 U S quart 946m1 Change engine oil and the oil filter after the first eight 8 hours of operation Thereafter change engine oil and oil filter everv 50 operating hours NOTE Additional Information on the engine oil svstem can be found in Part 5 of this manual Engine Oil and Cooling System STORAGE INSTRUCTIONS PREPARATION FOR STORAGE The engine should be started at least once every seven 7 days and allowed to run for at least thirty 30 minutes If this cannot be done and the engine is to remain unused longer than thirty 30 days it must be prepared for storage To prepare the unit for stor age proceed as follows 1 Start the engine and let it warm up
63. NTS There are no adjustments on the fuel lockoff solenoid or the secondary regulator This system is NOT equipped with a load block THE LP GAS REGULATOR The secondary regulator is GARRETSON Model KN It is designed for simplicity and simple operation The regulator is suitable for use with low pressure vaporized gaseous fuels where dependable starting is a requirement Recommended inlet pressure to the regulator is 11 inches water column The regulator comes with a 314 inch fuel inlet and a 3 8 inch NPT fuel outlet The LOCKOFF ADJUSTMENT SCREW shown in Figure 2 has been preset at the factory No additional adjustment is authorized Figure 2 LP Gas Regulator DANGER DO NOT ATTEMPT TO ADJUST THE GAS REGULATOR REGULATOR ADJUSTMENTS SHOULD BE ATTEMPTED ONLY BY QUALIFIED GAS SERVICE TECHNI CIANS WHO HAVE THE KNOWLEDGE AND SPECIALIZED EQUIPMENT FOR SUCH ADJUSTMENTS TESTING THE FUEL LOCKOFF SOLENOID GENERAL The fuel lockoff solenoid is energized open by 12 volts DC power from the A6060 circuit board during engine cranking The solenoid can also be energized open without cranking by actuating the fuel primer switch on the generator panel Continued Page 4 2 1 Section 4 2 SHUTOFF VALVE AND REGULATOR TEST PROCEDURE 1 Set a volt ohm milliammeter VOM to read battery voltage 12 VDC 2 Connect the VOM test leads across Wire 14 Red at the sole noid and a clean frame ground 3 Set the f
64. OKE SOLENOID ADJUSTMENT Loosen the two screws that retain the choke solenoid to its cover Adjust axial movement of the solenoid plunger by sliding the solenoid in the slotted screw holes of the cover Adjust plunger axial movement until with the carbure tor choke valve closed the plunger is bottomed in the solenoid coil That is until the plunger is at its full actuated position With the choke valve choke plate closed and the plunger bottomed in its coil tighten the two screws L Loosen 2 screws and slide solenoid In the slots of choke mount cover With carburet or choke plate clos ed plunger must be bottomed in coil Figure 2 Choke Adjustment Page 3 5 1 Section 3 5 AUTOMATIC CHOKE Page 3 5 2 Section 3 6 SPEED CONTROL SYSTEM GENERAL The AC generator s output voltage is controlled by a computerized speed control system This system changes engine speed in response to changes in the AC output voltage at varying engine loads The speed control system consists of a the A6060 circuit board and b a stepper motor A6060 CIRCUIT BOARD This circuit board utilizes a closed loop proportional derivative controller circuit which regulates the gener ator s RMS voltage by changing engine speed The system attempts to maintain an output voltage of about 115 volts at the lowest rpm and 120 volts up to the maximum rpm The A6060 circuit board controls a stepper motor by calculating t
65. OR COMPONENTS INTRODUCTION Major components of the generator proper are shown in Figure 1 below External sheet metal and other unrelated components are omitted from the drawing for clarity These parts are Description Upper Fan Housing Upper Cooling Fan Permanent Magnet Rotor Rotor Hub Stator Retaining Ring Stator Assembly Stator Adapter Engine Lower Fan amp Flywheel Stepper Motor N O3 O1 PWM e Figure 1 Exploded View of Generator Proper UPPER FAN HOUSING As its name implies this component houses and shields the upper cooling fan See Figure 1 Item 1 UPPER COOLING FAN The Cooling Fan draws air into the generator through slots in the Upper Fan Housing It is fastened to and rotates with the Permanent Magnet Rotor PERMANENT MAGNET ROTOR Sixteen permanent magnets have been affixed to the Rotor A starter ring gear is welded to the Rotor The Rotor and Hub are balanced at the factorv as an assembly and must be replaced as an assembiv NOTE The hub MUST be properly aligned during reassembly The mounting bolt housing opening and magnet must be properly aligned In addition match marks between the Hub and Rotor must be aligned as indicated by an ALIGN MARKS FOR BALANCE decal During assembly use care to avoid damage to the Ignition Sensor DANGER The permanent magnet rotor pro duces an extremely strong magnetic force Use care durin
66. R Page 8 3 Part 8 SPECIFICATIONS amp CHARTS MODEL GENERAL SPECIFICATIONS GV 220 BORE 2 95 inches 75mm STROKE 1 93 inches 49mm DISPLACEMENT 216 5cc OIL CAPACITY W O FILTER CHANGE WITH FILTER CHANGE MODEL VALVE TRAIN 21 ounces 620ml 29 5 ounces 870 ml GV 220 VALVE SEAT WIDTH DESIGN WIDTH 0 034 0 044 inch 0 87 1 13mm VALVE SEAT ANGLE 45 degrees VALVE MARGIN DESIGN MARGIN 0 034 0 044 inch 0 87 1 13mm INTAKE VALVE STEM DIAMETER DESIGN DIAMETER 0 274 0 275 inch 6 965 6 980mm EXHAUST VALVE STEM DIAMETER DESIGN DIAMETER 0 273 0 274 inch 6 965 6 980mm TAPPET DIAMETER INTAKE AND EXHAUST DESIGN DIAMETER 0 293 0 294 inch 7 457 7 475mm VALVE SPRINGS FREE LENGTH FORCE REQUIRED TO COMPRESS SPRING TO 1 39 INCH 35 2mm 2 074 inch 52 69mm 19 8 21 8 pounds 9 0 9 9kg VALVE CLEARANCE INTAKE EXHAUST 0 001 0 0022 inch 0 030 056mm 0 0018 0 003 in 0 07 0 046mm VALVE GUIDES DESIGN DIAMETER ALLOWABLE END PLAV Page 8 4 0 237 0 2364 inch 6 02 6 005mm CRANKSHAFT END PLAV 0 006 0 023 inch 0 14 0 60mm MODEL CRANKCASE ASSEMBLY Part 8 SPECIFICATIONS amp CHARTS GV 220 CYLINDER BORE DESIGN DIAMETER 2 953 2 954 inch 75 000 75 025mm VALVE TAPPET BORE DESIGN DIAMETER 0 295 0 296 inch 7 494 7 520mm CRANKSHA
67. REMOVAL 30 9 LOCK WASHER 1 4 M6 70 1 BRACKET IGNITION SYSTEM 31 1 CONTACTOR STARTER 71 2 SPACER IGNITION COIL 32 1 BOOT CONTACTOR 72 1 MODULE IGNITION 33 1 SEAL OIL FILTER HOLE 73 1 ASSEMBLY IGNITION COIL 34 1 RETAINER SEAL 74 2 M6 1 0 x 35MM HEX HD CAPSCREW 35 4 FLAT WASHER M8 75 4 M6 1 0 HEX NUT 36 1 REGULATOR 76 2 M5 0 8 x 12MM PHILLIPS PAN HD 37 1 HOSE CLAMP 5 5 MACH SCR 38 1 SNAP BUSHING 77 2 M5 0 8 HEX NUT 39 2 SPECIAL LOCK WASHER M5 78 5 LOCK WASHER M5 40 2 118 32 HEX NUT 79 5 RUBBER U CHANNEL 41 2 8 LOCK WASHER 80 1 CRIMPTITE 10 24 x 3 8 42 2 HEX HD CAPS M6 1 0 x 16MM W L 81 1 WIRE ASSEMBLY BLOCKING DIODE WASHER 43 7 FLAT WASHER 10 M5 Page 1 7 5 Section 1 7 SHEET METAL Page 1 7 6 PART 2 ENGINE MECHANICAL COMPUTER CONTROLLED VARIABLE SPEED RV GENERATORS Series Impact 36 Plus TITLE GENERAL INFORMATION VALVE TRAIN PISTON RINGS CONNECTING ROD CRANKSHAFT amp CAMSHAFT NOTES Section 2 1 GENERAL INFORMATION INTRODUCTION The engine used on Impact 36 plus Series recreational vehicle AC generators is a Generac Series GV 220 vertical shaft single cylinder overhead valve type These engines are not equipped with a mechanical engine governor Instead variable engine speeds are controlled by a computer circuit board The circuit board signals a stepper motor to move the carburetor throttle linkage 4 CYCLE ENGINE THEORY GENERAL Series GV 220 eng
68. RETAINER to the crankcase interior Remove the RETAINER SPRING and BALL Clean all parts in solvent Inspect the BALL and RETAINER for damage exces sive wear Replace any damaged or worn compo nents Inspect the SPRING and replace if damaged or worn Apply a known test load to the SPRING sufficient to compress the spring to a length of 1 03 inch 26 3mm The amount of the test load at the stated spring length should be as follows FORCE REQUIRED TO COMPRESS RELIEF VALVE SPRING TO 1 03 INCH 26 3mm 0 86 0 95 pounds 0 43 0 39 kg If the test load at the stated length is not within limits replace the SPRING BREATHER ASSEMBLY DESCRIPTION A crankcase breather is located in the crankcase assembly Section 5 1 ENGINE OIL SYSTEM The breather serves to maintain a partial vacuum in the engine crankcase to prevent oil from being forced past oil seals gaskets or rings See Figure 6 A reed type breather valve permits excess pressure to be vented out of the crankcase and to atmosphere through a breather tube A breather retainer limits the movement of the breather valve Two small oil return holes in the breather cup allow condensed oil vapors to drain back to the crankcase A steel wool type breather separator separates the breather cup from the breather cover and breather tube opening TO AIR CLEANER BREATHER VALVE BREATHER X BAFFLE CUP Figure 6 Breather Assembly INSPECTION Remove t
69. ROL SYSTEMS Federal and state laws have imposed strict evapora tive controls on gasoline fuel systems The recreation al vehicle industry has complied with such strict regu lations by using specially designed fuel tanks tank filler tubes and gas caps Special canisters are often used to collect the gasoline vapors rather than let them escape into the atmosphere Such systems are designed to operate within very critical pressure ranges For that reason the vehicle manufacturer s fuel supply system design must not be Page 3 1 1 Section 3 1 INTRODUCTION TO FUEL SYSTEM altered Service technicians working on the RV gener ator systems must not do anything that might change the vehicle fuel system design CUSTOMER CONNECTION FILTER Figure 2 Typical Gasoline Fuel System Page 3 1 2 Section 3 2 AIR CLEANER AND INTAKE AIR CLEANER DESCRIPTION The air cleaner assembly consists of a an air clean er BASE b a PAPER FILTER and c a COVER See Figure 1 Figure 1 Engine Air Cleaner SERVICING THE AIR CLEANER Clean or replace the PAPER FILTER every 25 hours of operation or once each year whichever comes first 1 Loosen the two screws that retain the air cleaner COVER and remove the COVER 2 Remove the PAPER FILTER 3 Clean the PAPER FILTER by tapping gently on a flat surface If PAPER FILTER is extremely dirty replace it 4 Clean the air cleaner BASE and COVER then install the ne
70. Rectifier but no voltage or a low voltage is mea sured between the BCR s Wire 55 terminal and ground the Battery Charge Rectifier BCR is defective Figure 4 Battery Charge Circuit TESTING THE BATTERY CHARGE CIRCUIT Test the Battery Charge winding as follows 1 Disconnect Wire 77 at the Battery Charge Rectifier BCR 2 Disconnect Stator output Wire 66 at the Battery Charge Rectifier BCR 3 Disconnect Wire 55 4 Set a VOM to its Rx1 scale and zero the meter 5 Connect the VOM test leads across Wires 77 and 55 then across Wires 66 and 55 Note the resistance reading in both cases Replace Stator Assembly if defective BATTERY CHARGE WINDING RESISTANCE ACROSS WIRES 66 TO 55 0 095 0 108 Ohm ACROSS WIRES 77 TO 55 0 095 0 108 Ohm 6 Use a VOM to measure AC voltage at the Wires 66 and 77 ter minals of the Battery Charge Rectifier with the unit running If no AC voltage is measured an open circuit exists in the wire 66 or 77 circuit 7 With engine running use a VOM to check for DC voltage between the Battery Charge Rectifiers Wire 55 and frame ground If AC voltage was present in step 6 but DC voltage is NOT present in this step the Battery Charge Rectifier BCR is defective Page 1 5 3 Section 1 5 COMPONENTS TESTING Page 1 5 4 Section 1 6 CONTROL PANEL CONSTRUCTION The panel is constructed of sheet metal and includes a panel box a panel back cover and a front control pane
71. Restrictions For conventional compartment mounted units the air inlet is generally provided in the compartment door 10 SQUARE INCHES OPTIONAL OPENINGS 40 SQUARE INCHES 7ANN MINIMUM OPENING Figure 2 Air Inlet in Compartment Door IMPORTANT IF YOU PLAN TO INSTALL THE GENERATOR IN A COMPARTMENT BE SURE TO LEAVE AT LEAST ONE INCH 2 recom mended OF CLEARANCE BETWEEN THE GEN ERATOR AND COMPARTMENT WALLS AND CEILING INCLUDE 26 GAUGE GALVANIZED STEEL LINING AND SOUND INSULATION WHEN YOU MEASURE FOR THIS 1 INCH 2 recom mended CLEARANCE When the unit is installed on a suspended mounting System one of several different methods of supplying air flow may be used as follows Provide a door in the vehicle skirt having an air inlet opening Figure 3 next page Using ductwork Figure 4 on next page The installer must be sure air is available to the top of the generator since air inlets are located at the top By providing an opening in the vehicle skirt and space above the generator for cooling air flow Figure 5 on next page Recommended clearance above the top of the generator is at least 2 inches 90909090905 ER 506 550505606 009090905 550506 x9 5 e 5 2 te dle x o 9 5 5 2 1 Section 5 2 ENGINE COOLING SYSTEM Figure 3 Suspended Mount Inlet Door Figure 4 Ductwork RECOMMENDED CLEARANCE 2 IN 51
72. S BETWEEN THE TANK AND SECONDARY REGULATOR ARE UNDER A POSITIVE PRES SURE ABOUT 11 INCHES OF WATER COL UMN HOWEVER GAS PRESSURE AT THE OUTLET SIDE OF THE SECONDARY REGU LATOR IS A NEGATIVE PRESSURE ABOUT 1 INCH WATER COLUMN THIS NEGATIVE PRESSURE CAN DRAW FLAME INSIDE A LINE OR FITTING AND CAUSE AN EXPLO SION IMPORTANT APPLY PIPE SEALANT TO THREADS OF ALL FITTINGS TO REDUCE THE POSSIBILITY OF LEAKAGE Page 4 1 3 Section 4 1 INTRODUCTION TO FUEL SYSTEM Page 4 1 4 Section 4 2 SHUTOFF VALVE AND REGULATOR GENERAL See Figure 1 The fuel shutoff valve lockoff solenoid and the secondary regulator are retained to a flat mounting bracket which in turn mounts to the gener ator base cover The fuel lockoff solenoid is retained to the mounting bracket by means of a u bolt The secondary regulator is retained to the mounting bracket with two 1 4 20 x 3 4 long capscrews ITEM DESCRIPTION LP Gas Regulator Fuel Lockoff Solenoid U Bolt 1 25 wide 5 16 i 8 3 4 NPT Street Elbow 3 4 NPT Close Nipple 3 8 NPT Street Elbow 1 2 x 3 8 NPT Fitting Hose Clamp 1 2 ID Hose 11 5 long 1 4 20 x 3 4 Capscrew 1 4 Lockwasher 5 16 Lockwasher 5 16 18 Hex Nut Regulator Mounting Bracket Sleeving 9 long co nn nm nw 2 2 1 Figure 1 Shutoff Valve amp Regulator ADJUSTME
73. THE TESTS Page 1 4 1 Section 1 4 INSULATION RESISTANCE TEST ALL STATOR WINDINGS TO GROUND Connect the ends of all Stator leads together Make sure none of the leads are touching any terminal or any part of the generator Connect one Tester probe to the junction of all Stator leads the other Tester probe to a clean frame ground on the Stator Apply a voltage of 1000 volts for about 1 second Follow the tester manufacturer s instructions carefully Some Hi Pot testers are equipped with a Breakdown light which will turn ON to indicate an insulation breakdown A Megger Megohmmeter will indicate the megohms of resistance Normal Stator winding insulation resistance is on the order of millions of ohms or megohms The MINIMUM acceptable insulation resistance reading for Stators can be calcu lated using the following formula MINIMUM INSULATION RESISTANCE VOLTS in megohms EXAMPLE Generator rated voltage Is 120 VAC Divide 120 by 1000 to obtain 0 12 Add 1 to obtain 1 12 Minimum Insulation resistance for the unit Is 1 12 megohms 1 TEST FOR SHORTS BETWEEN WINDINGS Figure 2 on the previous page shows the Stator leads that are brought out of the Stator Figure 3isa schematic representation of the eight 8 Stator wind ings To test for shorts between windings proceed as follows 1 Make sure all Stator output leads are isolated from each other
74. USE AN EXPLOSION ONLY COMPETENT QUALIFIED GAS SERVICE TECHNICIANS SHOULD BE ALLOWED TO INSTALL TEST ADJUST OR SERVICE THE GASEOUS FUEL SYSTEM INSTALLATION OF A GASEOUS FUEL SYSTEM MUST BE IN STRICT COMPLIANCE WITH APPLICA BLE CODES FOLLOWING INSTALLATION NOTHING MUST BE DONE THAT MIGHT RENDER THE SYSTEM IN NONCOMPLI ANCE WITH SUCH CODES DANGER USE ONLY APPROVED COMPO NENTS IN THE GASEOUS FUEL SYSTEM IMPROPER INSTALLATION OR USE OF UNAUTHORIZED COMPONENTS CAN RESULT IN FIRE OR AN EXPLOSION USE APPROVED METHODS TO TEST THE SYS TEM FOR LEAKS NO LEAKAGE IS PERMIT TED DO NOT PERMIT FUEL VAPORS TO ENTER THE VEHICLE INTERIOR ADVANTAGES OF GASEOUS FUELS The use of gaseous fuels may result in a slight power loss as compared to gasoline However that disad vantage is usually compensated for by the many advantages of gaseous fuels Some of these advan tages are A low residue content results in minimum carbon formation in the engine Reduced sludge buildup in the engine oil Reduced burning of valves as compared to gasoline No wash down of engine cylinder walls during cranking and startup Excellent anti knock qualities A nearly homogeneous mixture in the engine cylinders Fuel can be stored for long periods without break down FUEL SYSTEM COMPONENTS When the generator set is shipped from the factory the following fuel system components are included with the unit 1 A Fuel Lockoff
75. YSTEM COMPUTER CONTROLLED VARIABLE SPEED RV GENERATORS Series Impact 36 Plus NOTES Section 5 1 ENGINE OIL SYSTEM INTRODUCTION TO OIL SYSTEM The engine oil system serves to a reduce friction between parts b cool the engine and c establish a slightly negative pressure in the crankcase to prevent oil leakage Major components that will be discussed in this section include the following Oil Pickup Screen Oil Pump Crankshaft Oil Seals Pressure Relief Valve Breather Assembly Oil Sump Oil Filter Support Assembly OIL FLOW See Figure 1 The oil pump draws oil from the oil sump through an oil pickup screen and delivers it to the areas requiring lubrication as follows 1 Through a cored channel in the oil sump to the crankcase jour nal at one end of the crankshaft 2 Through the hollow camshaft to the camshaft bearing 3 Through a cored passage in the crankcase to the crankshaft journal 4 Through the crankshaft to the crankpin and connecting rod bearing Figure 1 Oil System Diagram OIL PICKUP SCREEN DESCRIPTION The oil pickup screen consists of a cylindrical screen which is open at one end only The screen s open end fits over a tubular protrusion in the oil sump just behind the oil filter support Also see Oil Filter Support Assembly INSPECTION To gain access to the screen remove the oil filter support and its gasket Pull the screen off its tub
76. ads across the center and Wire 18 terminals a With switch at START VOM should indicate infinity b With switch at STOP meter should read con tinuity Replace the switch if it is defective STARTER CONTACTOR WIRE AND CABLE CONNECTIONS The red positive battery cable connects to one of the starter contactor s large terminal lugs The unit s 15 amp fuse also attaches to this lug via Wire 13 The starter motor SM1 cable 16 attaches to the second terminal lug Wire 56 from the A6060 circuit board attaches to one of the small contactor terminals TESTING THE STARTER CONTACTOR To test the installed Starter Contactor proceed as fol lows 1 Set a volt ohm milliammeter VOM to read battery voltage 12 VDC 2 Connect the VOM test leads across the Wire 56 terminal of the Contactor and frame ground The meter should indicate zero volts 3 Hold the Start Run Stop switch at START and the VOM should read battery voltage and the Contactor should energize After reading the voltage release the switch If battery voltage is NOT indicated a problem exists elsewhere in the circuit 4 Connect the VOM test leads across the Wire 16 terminal lug and frame ground a Hold the Start Run Stop switch at START Contactor should actuate and the meter should indicate battery voltage b If battery voltage is not indicated replace the Starter Contactor c If battery voltage is indicated but engin
77. ally avail able The type shown has a Breakdown lamp which turns on to indicate an insulation breakdown during the test One common type of tester is the Megohmmeter which measures resistance in Megohms Figure 1 One Kind of Hi Pot Tester CAUTION When using a Megohmmeter or any other tester be sure to follow the manu facturer s instructions carefully All Stator leads must be isolated from other compo nents especially circuit boards before per forming tests The high voltages used in test ing insulation resistance will damage elec tronic components STATOR LEADS The following leads are brought out of the Stator and connected to various components in the unit WIRE COLOR CONNECTS TO AC1 Grey CB1A AC2 Yellow BR1 SL1 Orange CBIB SL2 Brown BR3 TIM1 Orange A6060 Circuit Board TIM2 Grey A6060 Circuit Board PS1 Red J1 PS2 Black J1 77 Brown Battery Charge Rectifier BCR 66 Brown Battery Charge Rectifier BCR 55 Black Grounding Terminal 1 ORANGE CI TM2 GREV PS2 BLACK QUEE PS1 RED AC2 YELLOW 4 AC1 GREY SL1 ORANGE Figure 2 Stator Leads PREPARATION FOR TESTS See Stator leads CHART above Disconnect and iso late all Stator leads ALL STATOR LEADS MUST BE DISCONNECTED AND ISOLATED BEFORE START ING
78. amperes For prevailing ambient temperatures below 32 F 0 C use a battery rated 95 amp hours and capa ble of delivering 450 cold cranking amperes BATTERY CABLES Battery cables should be as short as possible and of adequate diameter Cables that are too long or too small in diameter can result in voltage drop The volt age drop between battery terminals and the connec tion point at generator should not exceed 0 121 volts per 100 amperes of cranking current The cables should be carefully selected based on a cable length and b prevailing ambient temperatures Generally the longer the cable and the colder the ambient temperature the larger the required cable size The following chart applies CABLE LENGTH CABLE SIZE Feet Meters 0 to 10 0 to 3 2 11 to 15 3 4 4 5 0 16 to 20 4 5 to 6 000 For warm weather use No 2 cable up to 20 feet BATTERY CABLE CONNECTIONS 1 Connect the cable from the large Starter Contactor SC lug to the battery post indicated by a POSITIVE POS or 4 2 Connect the cable from its FRAME GROUND connection to the battery post indicated by a NEGATIVE NEG or continued Page 6 3 1 Section 6 3 ENGINE CRANKING SYSTEM BATTERY CONTINUED TESTING A BATTERY The best method of testing a battery is with an auto motive type battery hydrometer Some Maintenance Free batteries cannot be tested with a hydrometer Most batteries can be tes
79. as an inside cham fer which must face UP when installing the ring The top compression ring has a barrel shaped face and can be installed with either side up Section 2 3 PISTON RINGS CONNECTING ROD TOP COMPRESSION RING SS EITHER SIDE UP 2ND COMPRESSION RING CHAMFER FACES UP OIL CONTROL RING EITHER SIDE UP 7 Cd 2444 Figure 7 Ring Locations Piston Grooves CHECKING PISTON RING END GAP To check piston rings end gap proceed as follows see Figure 8 1 Locate a point inside the cylinder that is 2 75 inches 70mm down from top of cylinder This is approximately half way down 2 Place the ring into the cylinder Use the piston to push the ring squarely into the cylinder to the proper depth 3 Use a feeler gauge to measure the ring end gap If end gap is excessive rebore the cylinder to take oversize parts TOP RING END GAP GV 220 DESIGN GAP 0 005 0 016 inch 0 15 0 40mm WEAR LIMIT 0 024 inch 0 60mm Maximum SECOND RING END GAP GV 220 DESIGN GAP 0 006 0 016 inch 0 15 0 40mm WEAR LIMIT 0 024 inch 0 60mm Maximum OIL RING END GAP GV 220 DESIGN GAP 0 015 0 055 inch 0 38 1 40mm WEAR LIMIT 0 062 inch 1 60mm Maximum Figure 8 Ring End Gap CONNECTING ROD The connecting rod is manufactured of die cast alu minum Alignment marks are provided on the rod and on the connecting rod cap Be sure to align these marks when assembling the rod t
80. battery voltage should be available to the Ignition Module via Wire 14 RED wire And battery voltage should be available from the Ignition Module to the Ignition Sensor via a RED wire If this 12 VDC power supply is not available the ignition system will not function To check the power supply proceed as follows using a volt ohm milliammeter VOM 1 Gain access to the control panel interior 2 In the panel locate the 3 pin connector that interconnects the Ignition Module and the Ignition Sensor 3 Press down on the connector lock tang and disconnect the two connector halves NOTE A single large black lead carries the three leads from the Ignition Sensor to the 3 pin MALE connector The three leads from the Ignition Module brown green and red attach to the 3 pin FEMALE connector 4 Set the VOM to a scale that will allow battery voltage to be read about 12 volts DC 5 Connect the meter test leads across the center FEMALE pin RED wire and frame ground 6 Hold the Start Run Stop switch at START The meter should read battery voltage FROM IGNITION MODULE Figure 10 If battery voltage is NOT indicated go to Step 7 If battery voltage IS indicated go to CHECK IGNITION SENSOR 7 Now locate the 4 terminal connector in the panel Connect the VOM test leads across the terminal and frame ground Crank the engine and the VOM should read battery voltage a lf battery voltage is indicated now but wa
81. buretor at a high velocity The high velocity air flow past the carburetor venturi results in a drop in air pressure at the venturi throat This reduced air pressure draws fuel through the main nozzle that opens into the venturi which then mixes with the air in the air passage Page 3 4 1 Section 3 4 CARBURETOR CARBURETOR DISASSEMBLY See Figure 3 The carburetor can be disassembled as follows 1 Remove the BOWL NUT Item 3 and the FIBER WASHER Item 4 Then remove the FLOAT BOWL Item 5 2 Remove the FLOAT PIN Item 6 Then remove the FLOAT Item 7 and the INLET VALVE Item 8 3 Remove the IDLE SPEED SCREW Item 20 with SPRING Item 19 4 Rotate the THROTTLE VALVE Item 10 to its closed position and remove the SCREW Item 9 Remove the THROTTLE VALVE 5 Remove the THROTTLE SHAFT Item 14 along with the THROTTLE SHAFT SPRING Item 13 and the THROTTLE SHAFT SEAL Item 12 6 Remove the CHOKE VALVE SPRING RETAINER Item 18 Remove the CHOKE VALVE Item 17 Remove the CHOKE SHAFT Item 15 and the SHAFT SEAL Item 16 CLEANING AND INSPECTION 1 Separate all non metallic parts 2 Clean metallic parts in a solvent or a commercial cleaner Soak the parts no longer than about 30 minutes 3 Inspect throttle lever and plate Replace if worn or damaged 4 The float bowl must be free of dirt and corrosion Use a new float bow gasket when assembling the bowl 5 Check the float for da
82. ched to the pump s outlet side Pump outlet pressure should be 2 0 to 3 5 psi Page 3 3 1 Section 3 3 FUEL FILTER AND FUEL PUMP Page 3 3 2 Section 3 4 CARBURETOR GENERAL INFORMATION Proper engine performance depends on the carbure tion system The use of clean fresh gasoline and a well maintained air cleaner are extremely important to proper operation as well as engine reliability and power Most causes of carburetion problems are related to the use of stale gummy fuel and the ingestion of dirt Before servicing the carburetor be sure to check for evidence of these conditions Gasoline that is left in the fuel lines for long periods can form gum or varnish deposits that will adversely affect carburetor opera tion NOTE A commercial fuel stabilizer such as STA BIL will minimize the formation of um deposits during storage Add the stabilizer to the gasoline In the fuel tank or In the storage container Follow the ratio recommended on the stabilizer contain er Run the engine for about 10 minutes after adding stabilizer to allow It to enter the carbure tor STABIL Is a brand name fuel stabilizer that can be purchased In most automotive repair facili ties or in lawn and garden centers DESCRIPTION The carburetor used on GV 220 engines is a float type with fixed main jet Carburetor throttle position and engine speed are controlled by an electric stepper motor The stepper motor moves the throttle in
83. d as follows 1 Disconnect the following wires a Lead 1 Grey at CB1A b Lead AC2 Yellow at BR1 c Lead 511 Orange at CB1B d Lead 512 Brown at BR3 2 Make sure all of the disconnected leads are iso lated from each other and are not touching the frame during the test 3 Set a VOM to its Rx1 scale and zero the meter 4 Connect one test lead to AC1 and one test lead to AC2 Note the resistance reading 5 Connect one test lead to SL1 and one test lead to SL2 Note the resistance reading NOMINAL RESISTANCE POWER PHASE WINDINGS 0 414 to 0 465 ohm 55 BLACK 66 BROWN 77 BROWN 1 ORANGE H TM2 GREY PS2 BLACK KE PS1 RED AC2 VELLOWJ f 1 GREY SL1 ORANGE 512 BROWN Figure 1 Stator Leads B To test the Power Phase windings for a short to ground con dition proceed as follows 1 Make sure all leads are Isolated from each other and are not touching the frame 2 Set a VOM to its Rx10 000 or Rx1K scale and zero the meter 3 Connect one VOM test lead to the terminal end of Stator Lead AC1 the other test lead to a clean frame ground on the Stator a The meter should read infinity b Any reading other than infinity indicates a short to ground condition c Repeat 3 agai
84. d of the engine will result in an immediate shutdown This automatic generator shutdown will occur at engine speed above 4200 rpm SHORT CIRCUIT PROTECTION If the inverter senses a short circuit on the AC output side it will automatically shut the generator down INVERTER OVERHEAT CONDITION If the inverter overheats AC output will be shut off The engine will continue to run for approximately two minutes and then shut down The maximum ambient temperature rating is 120 F DC LINK VOLTAGE GREATER THAN 600 VDC If DC link voltage exceeds 600 VDC the inverter will shut off AC power output DC LINK UNDER VOLTAGE SHUTDOWN If DC link voltage drops below 100 VDC the inverter will shut off AC power output Page 6 5 2 Section 6 6 OPTIONAL REMOTE PANEL GENERAL An optional remote mounted Start Stop panel is avail able This panel will permit the generator to be started and stopped from some convenient remote location in the recreational vehicle REMOTE PLUG IN RECEPTACLE A plug in receptacle Figure 2 24 is provided on the generator set near the DC power wires Use this receptacle to connect an optional remote mounted start stop panel to the generator Installation of such a panel will permit you to start and stop the generator engine from any convenient location inside the vehi cle WIRE 18 WIRE 14 WIRE 17 WIRE 10 STOP ENGINE RUN CRANK GROUND SIGNAL
85. der head bolts then remove the cylinder head and head gasket NOTE Replace the head gasket every time the head is removed The new head gasket must be free of nicks and scratches as these could cause leakage Page 2 2 1 Section 2 2 VALVE TRAIN CYLINDER CRANKCASE CYLINDER HEAD BOLTS CYLINDER HEAD GASKET Figure 4 Cylinder Head Removal DANGER ALWAYS WEAR SAFETY GLASSES WHEN REMOVING THE VALVE SPRINGS 5 See Figure 5 next page Hold the valve with your fingers while compressing the spring with your thumb then proceed as fol lows a While the spring is compressed slide the larger hole of the valve spring retainer toward the valve stem b With the larger spring retainer hole around the valve stem release the spring c Remove the valve spring retainer the spring and the spring washer Figure 5 Removal of Valve Spring 6 Remove the intake and exhaust valves 7 Clean all parts Remove carbon from valve heads and stems 8 Inspect the valves and valve seats Service parts as outlined under Valve Service Page 2 2 2 VALVES Replace valves If they are damaged distorted or if the margin is ground to less than 0 039 inch 1 0mm If the valves are in useable condition use a valve grinder to grind the faces to a 45 angle Check valve stem diameter After the valves have been reconditioned they should be lapped with a suitable lapping tool and valve lap ping compound VALVE S
86. dicator Figure 8 Measuring Compression Release Lift INSTALLING THE CRANKSHAFT Before installing the crankshaft lubricate all bearing surfaces with engine oil Use oil seal protectors to prevent damage to seals during installation Install the crankshaft as follows 1 Lubricate all bearing surfaces with engine oil 2 Install the valve tappets 3 Support both ends of the crankshaft and carefully install into the crankcase 4 Rotate the crankshaft until the timing mark Figure 9 is toward the cam gear side of the crankcase INSTALLING THE CAMSHAFT Apply engine oil to the camshaft main bearing and to bearing bore in crankcase Carefully install the camshaft into the crankcase camshaft bore Hold the tappets out of the way during installation Align timing mark on camshaft gear with timing mark on crankshaft gear piston will be at top dead center See Figure 10 NOTE For Installation of the oil pump assembly oil pickup assembly and crankcase cover see Part 5 ENGINE OIL amp COOLING SYSTEM Page 2 3 7 Section 2 4 CRANKSHAFT AND CAMSHAFT CRANKSHAFT CAMSHAFT GEAR Figure 9 Timing Mark on Crankshaft Gear Figure 10 Alignment of Timing Marks Page 2 3 8 PART 3 GASOLINE FUEL SYSTEM COMPUTER CONTROLLED VARIABLE SPEED RV GENERATORS Series Impact 36 Plus TITLE INTRODUCTION TO FUEL SYSTEM AIR CLEANER amp AIR INTAKE FILTER amp FUEL PUMP CARBURETOR AUTOMATIC CHOKE SPEED
87. e power than on a conventional generator since it can be allowed to run at a higher speed When the load is reduced the engine can run at slower than the usual speeds This improves fuel economy and reduces engine noise The Impact Plus unit can be operated closer to its peak power point at all times because output volt age and current are functions of engine speed This allows for a much more compact generator design IMPACT PLUS SYSTEM OVERVIEW Figure 10 is a block diagram of the Impact Plus sys tem The major elements of the system are represent ed in the diagram Operation of the system may be described briefly as follows 1 The engine is directly coupled to a permanent magnet type Rotor so the Rotor runs at the same speed as the engine 2 As the Rotor turns its magnetic field cuts across the Stator windings to induce a voltage into the Stator ROTOR STATOR RECTIFIER Figure 10 Block Diagram of the Impact 36 Plus System Page 1 1 4 Section 1 1 GENERATOR FUNDAMENTALS 3 When the generator circuit breaker is turned to the ON position AC voltage is delivered to the Full Bridge Rectifier The AC volt age is rectified to DC and thus becomes DC Link voltage 4 AC voltage from the stator PS1 PS2 is delivered to the inverter This is used as the power supply for the inverter circuit board 5 AC voltage from the stator TIM1 TIM2 is delivered to the system
88. e 12 VDC to the Starter Contactor SC The SC contacts open and cranking ends 2 Choking action ends and the carburetor choke plate is posi tioned by the Choke Heater CH 3 Circuit board action continues to power the Wire 14 circuit fuel flow and ignition continue NORMAL SHUTDOWN When the Start Run Stop switch is held at STOP the Wire 18 circuit is connected to frame ground A6060 circuit board action then terminates the DC flow to the Wire 14 circuit 1 Fuel Pump FP shuts down 2 Ignition terminates 3 Engine shuts down ENGINE PROTECTIVE DEVICE SHUTDOWN Refer to Oil Filter Support on Page 5 1 3 and Section 6 5 The engine mounts a Low Oil Pressure Switch LOP and a High Oil Temperature Switch Section 6 5 also lists several other shutdown capabili ties of the Impact Plus generator system Section 6 2 A6060 CIRCUIT BOARD GENERAL The A6060 circuit board controls all phases of engine operation including cranking starting running and shutdown The circuit board interconnects with other compo nents of the engine electrical system The board Is powered by fused 12 VDC battery out put available to the board via Wire 15 T T 00000000 J1 0000000007 KT Figure 1 A6060 Circuit Board CIRCUIT BOARD CONNECTIONS RECEPTACLE J1 The A6060 circuit board mounts an 8 pin receptacle J1 An 8 pin connector pl
89. e PTO shaft by means of a conical washer and an M16 1 50 hex nut When assembling tighten the flywheel nut to 75 foot pounds ENGINE The engine is a single cylinder 220 cc overhead valve type manufactured by Generac Power Systems Inc Page 1 2 2 STEPPER MOTOR The Stepper Motor Figure 3 consists of a stepper motor along with a gear and cam arrangement which allows motor movement to change the engine carbu retor throttle setting The Motor is controlled by output signals from the Computer Control Circuit Board which calculates the number of steps the stepper needs to take and generates the required signals to the Motor The circuit board signals the Motor to actu ate in response to changes in AC output voltage Thus in response to decreasing AC output voltages the Motor will increase the throttle setting and engine speed will increase Conversely Increasing AC out put voltages will cause the Motor to decrease throttle setting and engine speed will decrease 55 BLACK 66 BROWN 77 BROWN gt 1 ORANGE TM2 GREY PS2 BLACK a Is PS1 RED AC2 YELLOW AC1 GREY SL1 ORANGE SL2 BROWN Figure 4 Stator Pictorial View Section 1 2 MAJOR GENERATOR COMPONENTS POWER ik 1 PHASE 1 L b POWER PERO PHASE 2 SL2 amp 51
90. e does not crank check the Starter Motor and its cable Section 6 3 ENGINE CRANKING SYSTEM Figure 3 Starter Contactor STARTER MOTOR DESCRIPTION The Starter Motor is a 12 volts negative ground type It is capable of operating on heavy duty battery input at temperatures as low as 30 F without any signifi cant change in performance Its pinion is a 10 tooth type having a 20 pressure angle TESTING Connect the test leads of a VOM across the Starter Motor terminal and case Hold the Start Run Stop switch at START The VOM should read battery voltage and the Starter Motor should turn If VOM reads 12 volts DC and the Motor does not turn the Motor is probably defective Remove the Motor and test with a 12 volts DC power source Replace the Starter Motor if defective Figure 4 Starter Motor Page 6 3 3 Section 6 3 ENGINE CRANKING SYSTEM Page 6 3 4 Section 6 4 ENGINE IGNITION SYSTEM INTRODUCTION The engine ignition system consists of the following major components gnition Cage Assembly gnition Sensor Assembly gnition Module IM e Ignition Coil IC Spark Plug SP1 IGNITION CAGE ASSEMBLY An IGNITION CAGE ASSEMBLY is factory installed onto the permanent magnet rotor hub Two magnets are installed in the cage as shown in Figure 1 50 apart so that the north pole of one magnet faces away from the cage outer periphery and the north pole of the other magnet face
91. ectly proportional to the increase in current flow and the field is distributed along the full length of the conductor The direction of the lines of force around a conduc tor can be determined by what is called the right hand rule To apply this rule place your right hand around the conductor with the thumb pointing in the direction of current flow The fingers will then be pointing in the direction of the lines of force NOTE The right hand rule is based on the cur rent flow theory which assumes that current flows from positive to negative This is opposite the electron theory which states that current flows from negative to positive Figure 2 The Right Hand Rule ELECTROMAGNETIC INDUCTION An electromotive force EMF or voltage can be pro duced in a conductor by moving the conductor so that it cuts across the lines of force of a magnetic field Similarly if the magnetic lines of force are moved so that they cut across a conductor an EMF voltage will be produced in the conductor This is the basic principal of the revolving field generator Figure 3 below illustrates a simple revolving field generator The permanent magnet Rotor is rotated so that its lines of magnetic force cut across a coil of wires called a Stator A voltage is then induced into the Stator windings If the Stator circuit is completed by connecting a load such as a light bulb current will flow in the circuit and the bulb will light
92. ed to a complete circuit the electrons are forced to flow in a single direction rather than their free or orbiting pattern The resistance of a conductor depends on a its physical makeup b its cross sectional area c its length and d its temperature As the conductor s tempera ture increases its resistance increases in direct pro portion One 1 ohm of resistance will permit one 1 ampere of current to flow when one 1 volt of electro motive force EMF is applied OHM S LAW A definite and exact relationship exists between VOLTS OHMS and AMPERES The value of one can be calculated when the value of the other two are known Ohm s Law states that in any circuit the current will increase when voltage increases but resistance remains the same and current will decrease when resistance Increases and voltage remains the same Figure 7 If AMPERES is unknown while VOLTS and OHMS are known use the following formula _ VOLTS AMPERES OHMS If VOLTS is unknown while AMPERES and OHMS are known use the following formula VOLTS AMPERES x OHMS If OHMS is unknown but VOLTS and AMPERES are known use the following OHMs VOLTS AMPERES REACTANCE IN AC CIRCUITS GENERAL When direct current DC is flowing the only opposi tion to current flow that must be considered is resis tance ohms This is also true of alternating current AC when only resistance type loads such as heating and lamp elemen
93. erter unit If a greater length is needed contact Generac DO NOT ATTEMPT TO SHORTEN OR LENGTHEN THE SUPPLIED sensing harnesses The DC power wires may be cut to the required length Allow enough length to make connection Coil excess inside J Box CAUTION Do not install the inverter in the engine compartment Overheating may result TESTING THE INSTALLATION Generac recommends testing the installation to be sure adequate cooling air flow is available to the unit before placing the unit into service If the unit shows signs of overheating you will need to enlarge the air openings Never place a unit into service until absolutely certain that cooling and ven tilation is adequate IMPORTANT YOU MUST TEST THE INSTALLA TION ESPECIALLY IF YOU BRING IN AIR FROM BELOW THE GENERATOR SET PART 6 ENGINE ELECTRICAL SYSTEM COMPUTER CONTROLLED VARIABLE SPEED RV GENERATORS Series Impact 36 Plus TITLE ENGINE DC CONTROL SYSTEM A6060 CIRCUIT BOARD ENGINE CRANKING SYSTEM ENGINE IGNITION SYSTEM ENGINE SHUTDOWN FEATURES OPTIONAL REMOTE PANEL NOTES Section 6 1 ENGINE DC CONTROL SYSTEM GENERAL The engine DC control system consists of all those electrical components required for cranking starting and running the engine These components include the following 1 Engine cranking system components a A 12 VDC battery b A Start Run Stop Switch SW1 c A Starter Contactor Starter Relay SC d
94. es an assist In removing the wrist pin snap ring To remove the piston from the connecting rod pro ceed as follows 1 Move the snap ring around until Its protruding end is aligned with the notched out oil hole Use needle nose pliers to turn the snap ring and pull it toward vou 2 With one snap ring removed slide the wrist pin out of the pis ton boss This will separate the piston from the connecting rod F figure 2 Piston Pin Removal CHECK FOR PISTON WEAR The piston is slightiv elliptical It s smaller diameter is in line with the wrist pin boss It s larger diameter is 90 from the wrist pin boss NOTE An assembly mark Is provided on the pis ton This mark should face the flywheel end of the crankshaft 3 00 position during reassembly DIAMETER 753 2 754 in 69 939 69 959mm MINOR DIAMETER 2 747 2 748 in 69 789 69 809mm MEASURE AT A POINT 1 4 1 6 inches 35 5 40 5 mm FROM TOP OF PISTON Figure 3 Elliptical Shape of Piston To check the piston for wear proceed as follows 1 Minor Diameter At a position directly in line with the wrist pin hole measure from top of piston down to a distance of 1 4 1 6 inches 35 5 40 5mm This is the minor diameter Measure at this point to check for wear 2 Major Diameter At a point 90 from the wrist pin bore measure down 1 4 1 6 inches 35 5 40 5mm This is the major diame ter Measure at this point to check for piston wear Replace t
95. es the AC generator components from the engine The engine Itself is enclosed by a BASE HOUSING WRAPPER Item 4 a FRAME Item 24 and a BELLY Item 23 These components are sealed by means of rubber SEALS Items 3 to prevent The LOWER FAN attaches to the engine shaft and is enclosed in a LOWER FAN HOUSING Item 19 Air is drawn Into the enclosed area around the engine and forced out of the LOWER FAN HOUSING Removal of sheet metal will be necessary for many repairs and for replacement of most parts Impact Plus Generator CONTROL PANEL S BOX DIVIDER PLATE ROCKER COVER 1 Page 1 7 1 Section 1 7 SHEET METAL EXPLODED VIEW OF SHEET METAL GASOLINE UNITS TO CARBURETOR Page 1 7 2 Section 1 7 SHEET METAL PARTS LIST FOR SHEET METAL GASOLINE UNITS ITEM QTY DESCRIPTION ITEM DESCRIPTION 1 1 PLATE DIVIDER 42 2 HEX HD CAPSCR M6 1 0 x 16MM 2 2 M6 1 0 HEX NUT W LOCKWASHER 3 1 SEAL RUBBER EXTRUSION 3 5 FT 44 3 SPECIAL LOCK WASHER M6 4 1 WRAPPER BOX 45 1 GROUND STRAP UNIT 5 31 M5 8 x 10MM LONG 47 1 1 8 x 3 16 NPT 90 DEG 6 2 MOUNTING RAILS BARBED FITTING 7 12 M8 LOCK WASHER 48 1 BRACKET MUFFLER HANGER 8 4 M8 1 25 x 35MM HEX HD CAPSCR 49 1 1 4 FU
96. essary 2 If oil pressure is actually low as indicated by the external gauge see Section 5 1 ENGINE OIL SYSTEM 3 If oil pressure is good and oil pressure switch is good go to Test 27 Page 7 2 16 TEST 27 TEST OIL TEMPERATURE SWITCH DISCUSSION See Section 6 5 ENGINE SHUTDOWN FEATURES TEST PROCEDURE See Section 6 5 RESULTS NOTE The generator will shutdown if the 12 pin connector is disconnected and the circuit breaker is turned on In order to perform the running diagnostic tests you must jump pin 10 to pin 11 This will enable the unit to continue to run with the circuit breaker turned to the ON posi tion See Figure 10 on page 7 2 17 TEST 28 DC LINK VOLTAGE TEST 1 Disconnect the 12 pin connector from the inverter Disconnect the Red Black Blue Green DC Link wires from the inverter Note Cap the DC Link wires with a wire nut for safety 2 On units with A6060 circuit board revision D or higher soft ware jump pin 10 to pin 11 on the 12 pin cable previously removed from the inverter The 12 position cable should be connected to the 12 pin socket on the generator control panel This will enable the generator to run with CB1 turned ON 3 Turn CB1 to ON position Start generator The engine should run at approximately 3300 rpm 4 Set VOM to DC Measure DC Link voltage between the Red and Blue wires place Red test lead to red wire and Black test lead to the Blue wire DC
97. ff intermittently a Stepper Motor failure b Connection to Stepper Motor broken or disconnected c Stepper Motor not properly connected Replace Stepper Motor Repair or replace connections Reconnect Stepper Motor 6 Engine starts but Stepper Motor does not move Shut down occurs after several seconds a Stator Timing winding is open b Timing winding in Stator shorted to ground a Repair replace bad wire s TIM1 TIM2 or replace Stator b Replace Stator Page 7 1 1 Section 7 1 GENERATOR amp SPEED CONTROL SYSTEM Page 7 1 2 Section 7 2 ENGINE DC CONTROL SYSTEM TROUBLESHOOTING INTRODUCTION This Section contains troubleshooting information pertaining to the engine DC control system The section is divided into two parts i e troubleshooting flow charts and diagnostic test procedures Use the flow charts and the test procedures in conjunction with one another The first step in troubleshooting is to identify the problem After identifying the problem go to the flow chart that best describes it Perform each test in the flow chart and follow the flow chart arrows and instructions If you need instructions for any test refer to the applicable diagnostic test procedure Problem solving on the computer controlled generator is somewhat more complex than problem solving on con ventional units The A6060 circuit board in addition to its voltage and frequency control functions
98. g Ignition Module Section 6 5 SHUTDOWN FEATURES GENERAL The engine mounts an Oil Pressure Switch LOP and an Oil Temperature Switch HTO These two switch es in conjunction with the A6060 circuit board pro tect the engine against a low oil pressure and b high oil temperature The engine protective circuit Is shown in Figure 1 OIL PRESSURE SWITCH DESCRIPTION The Oil Pressure Switch has normally closed contacts which are held open by engine oil pressure during cranking and running Should oil pressure drop below approximately 5 psi the switch contacts will close to complete the Wire 85 circuit to ground A6060 circuit board action will then de energize the Wire 14 circuit and the engine will shut down The A6060 circuit board provides a time delay to allow oil pressure to build during startup to prevent premature shutdown TESTING THE SWITCH Use a volt ohm milliammeter VOM to test the oil pressure switch Connect the VOM test leads across the switch terminal and the switch body With the engine shut down the meter should read continuity a very small resistance is acceptable With engine running the meter should read infinity OIL TEMPERATURE SWITCH DESCRIPTION This thermostatic switch has normally open contacts Should engine oil temperature exceed a preset safe value about 293 F the switch contacts will close On closure of the Switch contacts the Wire 85 circuit will be connected
99. g installation to avoid pinched fingers ALIGN MARKS FOR BALANCE 6 ur i 4 1 2 Hub 3 Ring Gear 4 Ignition Cage 5 Rotor 6 Fan Clips Figure 2 Permanent Magnet Rotor Assembly Page 1 2 1 Section 1 2 MAJOR GENERATOR COMPONENTS ROTOR HUB See Figure 2 on previous page The Rotor Hub is bal anced with the Rotor and must be replaced with the Rotor as an assembly Part of the engine ignition sys tem is pressed onto the Hub and can be replaced only as part of the Rotor and Hub assembly STATOR RETAINING RING The Stator Retaining Ring is made of die cast alu minum Four hex head capscrews with lockwashers pass through holes in the Retaining Ring to retain the Stator Assembly to the Stator Adapter Item 7 Figure 1 STATOR ASSEMBLY The 2 phase Stator is made up of six 6 windings with leads brought out as shown in figure 4 Figure 5 is a schematic representation of each stator winding Note that there are two 2 power phase windings Leads AC1 AC2 SL1 and SL2 a timing winding Leads TIM1 and TIM2 a power supply winding Leads PSI PS2 and a dual battery charge winding Leads 55 66 77 STATOR ADAPTER The Adapter is retained to the engine by means of four hex head capscrews The Stator is retained to the Stator Adapter and is sandwiched between the Adapter and the Stator Retaining Ring LOWER FAN amp FLYWHEEL The Lower Fan and Flywheel are retained to the engin
100. he piston if wear limits are exceeded 3 Check wrist Pin for Looseness A rough check for wear in the wrist pin wrist pin bore in the piston or wrist pin bore in the connecting rod is to check for looseness or play with the piston assembled to the rod Looseness or play indicates a worn wrist pin or a worn bore in the piston or connecting rod Page 2 3 1 Section 2 3 PISTON RINGS CONNECTING ROD Figure 4 Piston Minor Diameter PISTON MINOR DIAMETER GV 220 Design DIAMETER 2 747 2 748 inch 69 789 69 809mm Figure 5 Piston Major Diameter PISTON MAJOR DIAMETER GV 220 Design DIAMETER 2 753 2 754 inch 69 939 69 959mm NOTE Always apply engine oil to wrist pin and its bores during Installation Wrist pin fit is very close 4 Check Wrist Pin for Wear Measure the outside diameter of the wrist pin Also measure the inside diameter of the wrist pin bore in the piston and in the connecting rod Also check wrist pin length Replace any component that Is worn excessively WRIST PIN OUTSIDE DIAMETER GV 220 DESIGN DIAMETER 0 708 0 709 inch 17 989 18 000mm WEAR LIMIT 0 707 inch 17 969mm Minimum WRIST PIN LENGTH GV 220 DESIGN LENGTH 2 196 2 213 inch 55 8 56 2mm WEAR LIMIT 2 193 inch 55 7mm Minimum WRIST PIN BORE IN PISTON GV 220 DESIGN DIAMETER 0 708 0 709 inch 18 000 18 011mm WEAR LIMIT 0 710 inch 18 026mm Maximum CONNECTING ROD SMALL END I D GV 2
101. he board will signal the STEPPER MOTOR to reduce engine throttle setting until the desired voltage level is obtained c Output signals for operation of inverter Page 1 3 2 Section 1 4 INSULATION RESISTANCE DIRT AND MOISTURE If moisture is permitted to remain in contact with the generator Stator windings some of it will be retained in voids and cracks of the winding insulation This can eventually cause a reduction in insulation resistance and generator output may be affected Winding insulation in Generac generators is moisture resistant However prolonged exposure to water high humidity salt air etc will gradually reduce the resistance of winding insulation Dirt can make the problem even worse since it tends to hold moisture into contact with the windings Salt as from sea air can also worsen the problem since salt tends to absorb moisture from the air When salt and moisture combine they make a good electrical conductor Because of the detrimental effects of water dirt and salt the generator should be kept as dry and as clean as possible Stator windings should be tested periodi cally using a Hi Pot tester or a Megohmmeter If insu lation resistance is low drying of the unit may be nec essary If resistance is still low after drying the defec tive Stator should be replaced INSULATION RESISTANCE TESTERS One kind of insulation resistance tester is shown in Figure 1 below Other types are commerci
102. he breather hose Inspect it for cracks dam age hardening Replace if necessary Clean the breather cover and breather cup in com mercial solvent Check that the two small drain holes in the breather cup are open open with a length of wire if necessary Inspect the rivets that retain the reed type breather valve make sure they are tight Also check that the valve seats flat on the breather cup around the entire surface of the valve OIL SUMP DESCRIPTION The die cast aluminum oil sump is retained to the crankcase with six 6 flanged head bolts Install new gasket between the oil sump and crankcase each time the oil sump is removed Bores are provided in the oil sump for a oil pump rotors and camshaft b crankshaft c governor gear assembly d oil pickup Cored oil passages are pro vided from the pickup to the pump and from the pump to the crankshaft bore INSPECTION Clean the oil sump and blow dry with compressed air Use compressed air to blow out all oil passages Inspect the sump for cracks damage etc Check the following bores in the oil sump for wear CRANKSHAFT BEARING BORE DIAMETER GV 220 ENGINE DESIGN DIAMETER 1 104 1 105 inch 28 040 28 065mm WEAR LIMIT 1 106 inch 28 092mm Maximum CAMSHAFT BEARING BORE DIAMETER GV 220 ENGINE DESIGN DIAMETER 1 299 1 300 inch 33 00 33 03mm WEAR LIMIT 1 302 inch 33 06mm Maximum OIL PUMP INNER ROTOR SHAFT DIAMETER GV 220 ENGINE DESIGN DIAMETER 0
103. he number of steps the motor needs to take and then supplying the necessary signals to the motor to take those steps STEPPER MOTOR PROBLEMS INTRODUCTION Some stepper motor problems that might occur include the following Throttle linkage or carburetor throttle shaft sticking or linkage disconnected Stepper motor failed or seized A6060 CIRCUIT BOARD CONNECTOR Electrical connections to stepper motor broken or disconnected Electrical leads to stepper motor are connected wrong THROTTLE LINKAGE Check throttle linkage and carburetor throttle shaft for binding disconnected linkage This type of problem will usually result in the carburetor throttle lever not moving If the throttle lever does not move the throttle may be stuck at a permanently open throttle or a per manently closed throttle as follows 1 If the throttle is open engine will start but will accelerate quick ly and uncontrollably It will shut down when speed exceeds about 4200 rpm 2 If the throttle is closed engine will not accelerate under load STEPPER MOTOR FAILED OR SEIZED The engine will start but stepper motor will not turn If an open throttle condition exists either of the follow ing might occur 1 Engine may accelerate and shut down at 4200 rpm 2 Engine may shut down after 15 seconds due to an overvoltage condition If throttle is closed engine will be unable to acceler ate under load and AC
104. icate strength while most customary nuts do not have strength mark ings Mismatched or incorrect fasteners can cause damage malfunction and possible injury REPLACEMENT PARTS Components on Generac recreational vehicle generators are designed and manufactured to comply with Recreational Vehicle Industry Association RVIA Rules and Regulations to minimize the risk of fire or explo sion The use of replacement parts that are not in compliance with such Rules and Regulations could result in a fire or explosion hazard When servicing this equipment It is extremely important that all components be properly installed and tightened If Improperly Installed and tightened sparks could Ignite fuel vapors from fuel system leaks TABLE OF CONTENTS TITLE THE AC GENERATOR SERVICE ENGINE MECHANICAL MANUAL GASOLINE FUEL SYSTEM GASEOUS FUEL SYSTEM ENGINE OIL amp COOLING SYSTEM SERIES IMPACT 36 PLUS II ENGINE ELECTRICAL SYSTEM TROUBLESHOOTING SPECIFICATIONS amp CHARTS GENERATOR FUNDAMENTALS GENERATOR MAJOR COMPONENTS GENERAL OPERATIONAL ANALYSIS INFORMATION INSULATION RESISTANCE COMPONENTS TESTING COMPUTER CONTROL PANEL CONTROLLED VARIABLE SHEET METAL SPEED RV GENERATORS Series Impact 36 Plus Il Page 1 NOTES Section 1 1 GENERATOR FUNDAMENTALS MAGNETISM Magnetism can be used to produce electricity and electricity can be used to produce magnetism Much about magnetism canno
105. ines require four 4 strokes or cycles to complete one power cycle This is often called the 4 stroke 5 event cycle The 4 strokes and 5 events that occur are 1 Intake 2 compression 3 Ignition 4 power and 5 exhaust INTAKE STROKE FIGURE 1 The intake valve is open The exhaust valve is closed The piston travels downward creating a suction which draws the air fuel mixture from the carburetor into the cylinder and just above the piston COMPRESSION STROKE FIGURE 2 As the piston reaches bottom dead center BDC the intake valve closes The exhaust valve remains closed as well The piston starts to move outward in the cylinder Since both valves are closed the air fuel mixture in the cylinder is compressed POWER STROKE FIGURE 3 Both valves remain closed At some point before the piston reached top dead center TDC the spark plug fires to Ignite the fuel air mixture The piston moves to its top dead center position and the burning expand ing gases of combustion force the piston downward EXHAUST STROKE FIGURE 4 The expanding gases of combustion force the piston downward to its bottom dead center BDC position The exhaust valve then opens as the piston starts its movement toward top dead center TDC Piston movement then forces the exhaust gases out through the open exhaust valve The 4 stroke cycle of events then starts over again Figure 4 Exhaust Stroke Page 2 1 1 Secti
106. ing compressor contacts top of cylinder use a wood Page 2 3 3 Section 2 3 PISTON RINGS CONNECTING ROD hammer handle to gently tap the piston down into the cylinder 4 Check that the connecting rod s large diameter bearing is coat ed with oil as well as the crank throw and the connecting rod cap 5 Guide the large end of the connecting rod onto the crankshaft Install the connecting rod cap The match mark on the cap must be aligned with an identical mark on the rod Figure 10 6 Install the connecting rod cap bolts and tighten to the proper torque TIGHTENING TORQUE CONNECTING ROD CAP BOLTS GV 220 10 foot pounds 1 36 N m NOTE The connecting rod can be installed in either direction That is the cap marks on the rod and cap may face toward the installer or away from the installer The only requirement is that the assembly mark on top of piston be toward the fly wheel side of engine MATCH MARKS Figure 10 Match Marks on Rod and Cap CYLINDER SERVICE INSPECTION Check the cylinder for dirty broken or cracked fins Also look for worn or scored bearings or a scored cylinder wall Check the cylinder head mounting sur face for warpage If the head is warped it must be replaced If the cylinder bore is worn as evidenced by excessive ring end gap the cylinder should be replaced or rebored to 0 010 or 0 020 0 25 or 0 50mm oversize After reboring the cylinder to a specific oversize insta
107. ing the rocker arm jam nut with a crow s foot Tighten the jam nut to the specified torque After tightening the jam nut recheck the valve clearance to make sure it did not change JAM NUT TIGHTENING TORQUE GV 220 6 3 foot pounds Tighten jam nut to 85 85 inch pounds 7 10 N m Figure 18 Rocker Arm Cover Installation ROCKER ARM COVER INSTALLATION Place a new rocker arm cover gasket into place Then install the rocker arm cover Finally retain the cover with M6 1 00 x 12mm screws Page 2 2 5 Section 2 2 VALVE TRAIN Page 2 2 6 Section 2 3 PISTON RINGS CONNECTING ROD OVERSIZE PISTON amp RINGS Worn or scored cylinders may be rebored to 0 010 0 25mm or 0 020 0 50mm oversize Pistons and piston rings of matching oversize are available to fit the rebored cylinder CONNECTING ROD CONNECTING ROD CAP CONNECTING i ROD CAP BOLT Figure 1 Piston Rings and Connecting Rod PRIOR TO REMOVAL Before removing pistons rings and connecting rod clean all carbon from the cvlinder bore Carbon buildup in the cvlinder bore can cause ring breakage during piston removal REMOVAL Remove the connecting rod CAP BOLTS and the connecting rod CAP Then push the piston and con necting rod out through top of cvlinder PISTON REMOVE FROM CONNECTING NOTE An oil hole in the wrist pin area of the pis ton helps distribute oil to assist in cooling The oil hole also provid
108. it warm up 4 Apply electrical loads to at least 50 of the unit s rated capacity 5 When engine is thoroughly warmed up turn off or disconnect all electrical loads Then shut the engine down THE UNIT IS NOW READY FOR SERVICE ENGINE TUNE UP The following procedure may be used as a minor tune up On completion of the procedure the engine should run properly If it does not run properly addi tional checks and repairs are required 1 Service and repair engine air cleaners as necessary 2 Check engine oil level and condition of oil Add or change oil as required 3 Remove shrouding and clean away dirt from the engine cylin der head and cooling fins 4 Check fuel filters and clean or replace as necessary 5 Replace the spark plug with a Champion RC12YC or equiva lent plug a Set spark plug gap to 0 030 inch 0 76mm b Install new plug and tighten to 13 foot pounds 1 8 N m If a torque wrench is not available tighten spark plug as tight as possible with fingers and then 1 If plug Is RE USED tighten about 1 4 turn more with a wrench 2 If plug is NEW tighten it about 1 2 turn more with a wrench 6 Check that wiring is free of breaks abrasions and are properly routed 7 Check for spark as outlined in Ignition section of Part 6 of this manual 8 Run engine adjust carburetor if necessary and check opera tion Page 2 1 3 Section 2 1 GENERAL INFORMATION EXPLODED VIEW OF EN
109. k for breakage bending other damage These are roll pins which can be removed and replaced Tip Clearance of Rotor Inner Rotor 1 0 Rotor Thickness Figure 3 Oil Pump Check Points CRANKSHAFT OIL SEALS An oil seal is provided in the crankcase and in the oil sump to prevent leakage past the crankshaft jour nals See Figure 4 A defective or leaking seal can be replaced If the crankshaft has been removed from the engine old seals can be removed by tapping out with a screw driver or punching them out from inside Oil seal pullers are available commercially for seal removal with the crankshaft installed Always use a seal protector when installing the crank shaft into its crankcase bore and when installing the oil sump over the crankshaft Figure 4 Crankshaft Oil Seals Page 5 1 2 A ball type pressure relief valve is located in a bore of the crankcase The ball and spring are retained in the crankcase bore by a spring retainer The Relief Valve serves to limit oil pressure to a maxi mum value The ball will remain against its seat as long as oil pressure in the crankcase ail passage is below approximately 30 psi 29 kg cm Should oil pressure increase above that value the ball will be forced off its seat to relieve excess pressure into the crankcase 1 SCREW 2 RETAINER 3 SPRING 4 BALL Figure 5 Oil Pressure Relief Valve INSPECTION Remove the 8mm screw that retains the spring
110. l The panel box is retained to an engine genera tor divider plate by five M5 screws Removal of these screws will permit the panel to be removed from the divider plate and set out of the way with connecting wires still attached This will allow access to compo nents housed in the control panel COMPONENTS A heat sink bracket is attached to the engine genera tor divider plate for attachment of a heat sink to which four diode assemblies are mounted See Items 26 and 31 in the Exploded View of Control Panel Other components are also shown in the Exploded View Many of these components are part of the ENGINE ELECTRICAL SYSTEM Part 6 of this manual ITEMS 49 65 8 66 HARNESSES NOT SHOWN FOR CLARITY ITEM QTY DESCRIPTION ITEM DESCRIPTION BUS BAR OUTER 1 7 M5 0 8 x 12MM PHILLIPS PAN HD MACH SCR 2 1 BOX CONTROL TOP 1 0 x 10MM BOX CONTROL PANEL 10 32 x 1 PHIL MACH SCR 10 32 HEX NUT 8 x 10MM IG LOCK WASHER M5 0 7 x 16 UT Figure 1 Exploded View of Control Panel Page 1 6 1 Section 1 6 CONTROL PANEL Page 1 6 2 Section 1 7 SHEET METAL GENERAL See Exploded View of Sheet Metal on next page A DIVIDER PLATE Item 1 separat
111. ll an identically oversize piston along with identi cally oversized rings Page 2 3 4 Always resize the cylinder bore to EXACTLY 0 010 inch or 0 020 inch 0 25 or 0 50mm over the stan dard cylinder dimensions If this Is done accurately the service oversize ring and piston will fit and correct clearances will be maintained STANDARD CYLINDER BORE DIAMETER MINIMUM 2 7560 inches 70 000mm MAXIMUM 2 7570 Inches 70 025mm To rebore the cylinder use a commercial hone of suitable size chucked In a drill press having a spindle speed of about 600 rpm Use the stones and lubrica tion recommended by the hone manufacturer to pro duce the proper cylinder bore finish Proceed as fol lows 1 Start with coarse stones Center the cylinder under the drill press spindle Lower the hone so that the lowest end of the stone contacts the lowest point in the cylinder bore 2 Begin honing at bottom of cylinder Move the hone up or down at about 50 strokes per minute to avoid cutting ridges In the cylinder wall Every fourth or fifth stroke move the hone far enough to extend it one 1 Inch beyond the top and bottom of the cylinder bore 3 Every 30 or 40 strokes check the bore for size and straight ness If stones collect metal clean them with a wire brush 4 Hone with coarse stones until the cylinder bore is within 0 002 inch 0 05mm of the desired finish size Then replace the coarse stones with burnishing stones and continue until b
112. ly 2700 rpm 4 Turn CB1 to the ON position 5 Voltage across the floating power supply should be approxi mately 30 to 34VAC at approximately 3400rpm 6 If results are lower there is a possible stator problem Proceed to Test 34 TEST 33 TIMING WINDING TEST 1 Disconnect the timing winding from receptacle J5 on the A6060 circuit board orange and grey wires 2 Disconnect the 12 position harness from the inverter 3 Two jumper wires with alligator clips are required 4 Attach a jumper from Wire 15 located at the fuse holder to Wire 14 located at the four tab terminal block in the control panel This will enable fuel and ignition functions Connect positive lead to Reading should be Signal Circuit Pin 2 En Com Pin 1 PWM1 1 25 to 1 5v Signal Circuit 2 Test With DVOM Set At Resistance Range Pin 2 En Com Connect negative lead to Pin 3 PWM2 1 25 to 1 5v Connect positive lead to Reading should be Temperature Circuit Pin 9 0 V 10 kOhm 25 C 500 Ohms Pin 10 TEMP Sense Circuit NTC thermistor if inverter is hot resistance may be 3 Test With DVOM Set At AC Volts Pin 9 0 V Connect negative lead to Pin 11 SENSE 20 kOhm 200 Ohm several kOhm lower If inverter is cold resistance may be several kOhm higher Connect positive lead to Reading should be Fan Test Pin 9 0 V Pin 4 Wire 14 See Note
113. mage Replace If damaged The float setting is fixed and non adjustable 6 The carburetor body contains a main jet tube that is pressed in to a fixed depth Do NOT attempt to remove this tube Tube movement will adversely affect carburetor metering character istics 7 After soaking in solvent blow out all passages with com pressed air Page 3 4 2 Figure 3 Carburetor Exploded View 3 Bowl Nut 4 Fiber Washer 5 Float Bowl 6 Float Pin 7 Float 8 Inlet Valve 9 Screw 10 Throttle Valve 11 Body 12 Throttle Shaft Seal 13 Throttle Shaft Spring 14 Throttle Shaft 15 Choke Shaft 16 Choke Shaft Seal 17 Choke Valve 18 Choke Valve Spring Retainer 19 Idle Speed Screw Spring 20 Idle Speed Screw Section 3 4 CARBURETOR ADJUSTMENT The carburetor used on the GV 220 engine has a FIXED NON ADJUSTABLE Low Speed Jet ENGINE SPEED Engine speed is controlled by the A6060 circuit board That circuit board signals a stepper motor which moves the throttle linkage Engine speed will vary in response to changes in generator AC output voltage The circuit board monitors the demand for power and adjusts the engine speed accordingly This permits the engine to deliver only the power needed NOTE Do NOT attempt to accelerate the engine manually by grasping the throttle or throttle link age This win cause the system to enter a fault condition and
114. mer Switch SW2 is closed battery volt age is delivered to the engine Fuel Pump via Wire 13 7 5 Amp Fuse F1 the Switch contacts SW2 and Wire 14A The Fuel Pump will operate to draw fuel from the tank and prime the fuel lines NOTE On units with LP gas fuel system the Fuel Lockoff Solenoid FS will be turned on by closing the Primer Switch CRANKING When the Start Run Stop Switch is held at START the Wire 17 circuit from the A6060 circuit board is connected to frame ground Circuit board action then initiates the following events 1 Battery voltage is delivered to the Starter Contactor SC via Wire 56 a The SC coil energizes and its contacts SC close after a few seconds b Closure of SC contacts deliver battery voltage to the Starter Motor SM1 via Wire 16 The engine cranks 2 Battery voltage is delivered to the Wire 14 circuit a The Fuel Pump FP turns on b Power is available to the Ignition Module IM and ignition occurs c Power is available to the Inverter Fan for opera tion 3 A6060 circuit board action operates the automatic choke through Wire 90 Page 6 1 2 NOTE Also see Section 3 5 AUTOMATIC CHOKE and Section 6 2 6060 CIRCUIT BOARD RUNNING With fuel flow and ignition available the engine starts and runs The operator releases the Start Run Stop switch to its RUN position 1 The Wire 18 circuit is now open to ground Circuit board action terminates th
115. mn Page 4 1 1 Section 4 1 INTRODUCTION TO FUEL SYSTEM IMPORTANT CONSIDERATIONS CONTINUED NOTE A PRIMARY REGULATOR between the tank and the fuel lockoff solenoid is required to ensure that correct gas pressure is delivered to the lockoff solenoid The generator installer s connection point is at the fuel lockoff solenoid which has a 3 4 inch female connection A length of flexible hose is required between the fuel lockoff solenoid and rigid fuel piping to allow for vibration and or shifting of the unit This line must be at least six 6 inches longer than neces sary FUEL SUPPLY LINES When servicing or repairing the gaseous fuel system the following rules apply to gaseous fuel supply lines e The LP gas lines must be accessible but must also be protected against possible damage Do NOT connect electrical wiring to any gaseous fuel line Do NOT route electrical wiring alongside the gaseous fuel lines Route the gaseous fuel lines AWAY from hot engine exhaust mufflers and piping Gas lines should be retained with metal clamps that do not have any sharp edges VAPOR WITHDRAWAL Gaseous fuel lines and primary regulators must be properly sized to deliver adequate fuel flow to the generator engine The generator requires at least 67 cubic feet of gas per hour for its operation NOTE An existing primary regulator may be used to deliver gas to the fuel lockoff solenoid provid ed It has sufficient
116. n 100 F 38 C Use a soft brush or cloth to apply the solvent Use care to avoid damaging magnet wire or winding insu lation After cleaning dry all components thoroughly with moisture free low pressure compressed air DANGER DO NOT WORK WITH SOLVENTS IN ANY ENCLOSED AREA ALWAYS PRO VIDE ADEQUATE VENTILATION FIRE EXPLOSION OR OTHER HEALTH HAZARDS MAY EXIST UNLESS ADEQUATE VENTILA TION IS PROVIDED WEAR EYE PROTEC TION WEAR RUBBER GLOVES TO PROTECT THE HANDS CAUTION Some generators use epoxy or polyester base winding varnishes Use sol vents that do not at tack such materials DRYING THE GENERATOR GENERAL If testing indicates that the insulation resistance of a winding Is below a safe value the winding should be dried before operating the unit Some recommended drying methods include a heating units and b forced air HEATING UNITS If drying is needed the generator can be enclosed in a covering Heating units can then be installed to raise the temperature about 15 18 F 8 10 C above ambient FORCED AIR Portable forced air heaters can be used to dry the generator Direct the heated air into the generator s air intake openings Run the unit at no load Air tem perature at the point of entry into the generator should not exceed 150 F 66 C Page 1 4 3 Section 1 4 INSULATION RESISTANCE Page 1 4 4 Section 1 5 COMPONENTS TESTING INTRODUCTION Problems that occu
117. n using Stator Lead SL 1 Page 1 5 1 Section 1 5 COMPONENTS TESTING STATOR ASSEMBLY CONTINUED POWER f 1 amp PHASE 1 L POWER PRA PHASE 2 SL1 su b amp POWER SUPPLY PS1 PS2 TIMING TIM1 TIM2 b Figure 2 Schematic Stator Windings TESTING POWER SUPPLY WINDINGS A To test the Power Supply winding for an open circuit condition proceed as follows 1 Disconnect the 2 wire power supply from the generator See Figure 3 2 Set a VOM to its Rx1 scale and zero the meter 3 Connect one VOM test lead to Lead PS1 Red the other test lead to Lead PS2 Black The meter should indicate the resistance of the Power Supply winding NOMINAL RESISTANCE POWER SUPPLY WINDING 0 206 0 227 ohm B To test the Power Supply winding for a short to ground condi tion proceed as follows 1 Set the VOM to its Rx10 000 or Rx1 K scale and zero the meter 2 Connect one VOM test lead to Lead PS1 Red Connect the other test lead to a clean frame ground on the Stator The meter should read infinity NOTE Any reading other than Infinity Indicates the winding Is shorted to ground If winding is open or shorted the Stator should be replaced Page 1 5 2 TESTING THE TIMING WINDING A To test the Stator Timing winding for an open circuit condition proceed as follows 1 Disconnect the 2 pin connector from J5 of the A6060 circuit board See Figure 3 a Stator lead TIM1 Orange
118. nnect the meter test leads across the Wire 56 starter con tactor terminal and frame ground Page 7 2 12 3 Set the Start Run Stop switch to START The meter should indicate battery voltage RESULTS 1 No power to Wire 56 terminal go to Test 10 2 If power to Starter Contactor is good go to Test 11 Figure 5 Starter Contactor TEST 10 CHECK A6060 CIRCUIT BOARD POWER SUPPLY DISCUSSION Fused battery voltage is delivered to the A6060 circuit board via Wire 15 If this power 12 VDC is not avail able to the board cranking and startup will not be possible This test will determine if battery voltage is available to the circuit board for its operation TEST PROCEDURE Set a VOM to read battery voltage 12 VDC Connect one VOM test lead to the Wire 15 terminal J2 5 on the A6060 circuit board Connect the other test lead to frame ground The meter should indicate battery voltage RESULTS If battery voltage is NOT indicated check Wire 15 between the 7 5 amp fuse and the A6060 circuit board Repair reconnect or replace the wire as needed m If Battery Voltage was indicated test for proper ground from the A6060 circuit board Set a VOM to read Resistance Measure from terminal J2 6 to the generator frame ground A Continuity reading should exist If open or high resistance is measured repair wires or ground connections 3 If 12 VDC was indicated go to Test 12 Section 7 2 ENGINE
119. normally open con tacts close On closure of the contacts battery power is delivered directly to the Starter Motor to crank the engine Page 7 2 11 Section 7 2 ENGINE DC CONTROL SYSTEM AC TROUBLESHOOTING This test will determine if battery voltage is available to the Starter Motor for cranking the engine TEST PROCEDURE 1 Set a VOM to read battery voltage 12 VDC 2 Connect the meter test leads across the starter terminal and frame ground 3 Hold the Start Run Stop switch at START The VOM should read battery voltage and the engine should crank RESULTS 1 If power supply is good and engine cranks stop tests 2 If power supply is good but engine does NOT crank replace the Starter 3 If power supply is bad go on to Test 9 4 If voltage drops during cranking i e from 12 VDC to 9 5 VDC or lower then check battery condition and cable sizes per the installation manual Verify that proper grounding of the genera tor exists Figure 4 Starter Motor TEST 9 CHECK WIRE 56 POWER TO STARTER CONTACTOR DISCUSSION When the Start Run Stop switch is set to START the A6060 circuit board must react by delivering bat tery voltage to the Starter Contactor coil via Wire 56 Without this battery voltage the Contactor will not energize and battery output will not be delivered to the Starter Motor The engine will not crank TEST PROCEDURE 1 Set a VOM to read battery voltage 12 VDC 2 Co
120. not include an armature and there is no air gap to adjust or breaker points to adjust or replace Section 6 4 ENGINE IGNITION SYSTEM TESTING FOR SPARK To test the ignition system a suitable spark tester may be used Such spark testers are commercially available Test the system as follows Warning Do NOT use a screwdriver to test for spark Personal injury or damage to equip ment may result 1 Disconnect the high tension lead from the spark plug 2 Attach the spark plug high tension lead to the spark tester ter minal 3 Connect the spark tester clamp to the engine cylinder head 4 Crank the engine rapidly Engine must be turning at 350 rpm or more If spark jumps the tester gap you may assume the igni tion system is operating satisfactorily If sparking across the tester gap does NOT occur go to CHECK POWER SUPPLY Figure 8 Testing for Spark CHECKING ENGINE MISS To determine if an engine miss is ignition related connect the spark tester in series with the spark plug s high tension lead and the spark plug Then start the engine If spark jumps the tester gap at regu lar intervals but the engine miss continues the prob lem is in the spark plug or in the fuel system Figure 9 Checking Engine Miss CHECK POWER SUPPLY When the engine is being cranked battery voltage should be available from the A6060 circuit board to a 4 terminal connector via Wire 14 From the 4 terminal connector
121. nt AC the electrons flow first in one direction then reverse and move in the oppo site direction They will repeat this cycle at regular intervals A wave diagram called a sine wave shows that current goes from zero to maximum posi tive value then reverses and goes from zero to maxi Page 1 1 2 mum negative value Two reversals of current flow is called a cycle The number of cycles per second is called frequency and is usually stated in Hertz e One Cycle Figure 5 Alternating Current Sine Wave VOLT The VOLT 15 the unit used to measure electrical PRESSURE or the difference in electrical potential that causes electrons o flow Very few electrons will flow when voltage is weak More electrons will flow as voltage becomes stronger VOLTAGE may be consid ered to be a state of unbalance and current flow as an attempt to regain balance One volt is the amount of EMF that will cause a current of 1 ampere to flow through 1 ohm of resistance Section 1 1 GENERATOR FUNDAMENTALS Conductor of a Circuit N OKM Unit measuring resistance or opposition to flow ANPERE Unit measuring rate of current flow number of elec trons past a given point i a YOLT Unit measuring force or difference in potential causing current flow Figure 6 Electrical Units OHM The OHM is the unit of RESISTANCE In every circuit there is a natural resistance or opposition to the flow of electrons When an EMF is appli
122. o the crankshaft Connecting rod bolts are of the washerless type The connecting rod and the connecting rod cap are a matched set and must be replaced as a matched set Figure 9 Connecting Rod ASSEMBLY AND INSTALLATION ASSEMBLY Use a ring expander when installing rings into the pis ton ring grooves Install the OIL RING ASSEMBLY first Then install the second compression ring with its Inside chamfer facing up Finally install the top compression ring When assembling the piston connecting rod and wrist pin the assembly marks on the piston must be toward the flywheel side of the engine Coat the wrist pin wrist pin bore in piston and wrist pin bore in the rod with engine oil Install one snap ring into the piston s wrist pin bore Then assemble the piston to the rod Slide the wrist pin through one piston bore through the rod bore and through the second piston bore until it contacts the snap ring Then install the second snap ring into the piston bore INSTALLATION Coat the cylinder walls with engine oil as well as the crank throw connecting rod bearing and connecting rod cap bearing Then install the rod and piston assembly as follows 1 Use a ring compressor to compress the rings into the piston ring grooves MAKE SURE ALL RINGS ARE FULLY COM PRESSED INTO THEIR GROOVES 2 Guide the connecting rod into the cylinder with assembly mark on piston toward the flywheel side of engine 3 When the r
123. oard will shut down the engine 4 17 When Wire 17 is connected to ground by holding Start Run Stop Switch at START cranking will occur 5 15 Fused battery voltage The Wire 15 circuit is electrically hot at all times provided the unit battery is connected 6 0 frame ground 7 90 Delivers 12 VDC to automatic choke solenoid coil while cranking only 8 56 Delivers 12 VDC to starter contactor while cranking only 9 14 Delivers 12 VDC during cranking and run ning to a Engine Fuel System b Engine Ignition System and c Remote Panel Lamp if so equipped 10 Not Used NOTE 1 See SHUTDOWN FEATURES In Section 6 5 Page 6 5 1 RECEPTACLE J3 The A6060 circuit board mounts a 6 pin receptacle J3 A 6 pin connector plug connects to the A6060 This harness then connects to Stepper Motor Signals from the A6060 circuit board control the Stepper Motor operation Refer to page 3 6 1 for test proce dures continued Page 6 2 1 Section 6 2 A6060 CIRCUIT BOARD CIRCUIT BOARD CONNECTIONS CONTINUED RECEPTACLE J4 The A6060 circuit board mounts a 3 pin receptacle J4 A 3 pin connector plug connects to the A6060 This harness then connects to Bridge Rectifier DC Link Voltage is supplied to the circuit board for volt age sensing RECEPTACLE J5 The A6060 circuit board mounts a 2 pin receptacle J5 A 2 pin connector plug connects to the A6060 This harness then connects to TIM1 TIM2 The
124. on 2 1 GENERAL INFORMATION TIMING Valve timing and ignition timing must be precisely controlled if the engine is to operate properly and effi ciently Intake and exhaust valves must open and close in a precise timed sequence if the four strokes are to occur Ignition must occur at exactly the correct piston position just prior to the start of the power stroke Timing of valve opening and closing as well as of spark occurrence is given in relation to the pis ton position and the degrees of crankshaft rotation Ignition Is timed to occur several degrees before top dead center TDC of the piston to allow time for the air fuel mixture to ignite and start to bum before the piston reaches top dead center There must be no leakage past the valves in their closed position or compression will not develop Likewise there must be no leakage past the piston RECOMMENDED FUELS GASOLINE FUEL SYSTEMS For models equipped with a gasoline fuel system the use of clean fresh UNLEADED regular grade gaso line is recommended Unleaded gasoline burns clean er extends engine life and promotes better starting by reducing carbon deposits in the combustion chamber Leaded Regular grade gasoline may be used if unleaded gasoline is not available The use of gasohol is NOT recommended If it must be used it should not contain more than 10 percent ethanol When gasoline containing ethanol is used special care is required when preparing
125. or lead TIM1 The meter should read infinity 6 Connect one test lead to Stator lead PSI the other to Stator lead TIM1 Infinity should be indicated Section 1 5 COMPONENTS TESTING 7 Connect one test lead to Stator lead PS1 the other to Stator lead 77 The VOM should read infinity 8 Connect one VOM test lead to Stator lead TIM1 the other test lead to Stator lead 77 Infinity should be Indicated TESTING THE BATTERY CHARGE CIRCUIT GENERAL The Stator is equipped with dual battery charge wind ings These windings deliver an AC output to a Battery Charge Rectifier BCR which rectifies it changes it to direct current or DC The direct current is delivered to the unit battery to maintain the battery in a charged state while the unit is running BATTERY CHARGE WINDING 55 66 77 m a Ri 15 Figure 3 Battery Charge Windings and Rectifier SYMPTOMS OF CIRCUIT FAILURE It is difficult to determine if the battery charge circuit is operating without testing for correct voltage If you suspect the battery charge circuit Is defective the fol lowing symptoms will usually point to a cause of the problem See Figure 4 1 If no AC voltage can be measured across Stator connections at the Battery Charge Rectifier BCR an open circuit condition probably exists in Wire 66 Brown or Wire 77 Brown 2 If AC voltage s available to the Wire 66 and 77 terminals at the battery Charge
126. ore is within 0 0005 inch 0 01 mm of the desired size 5 Install finishing stones and polish the cylinder to its final size 6 Clean the cylinder with soap and water Dry thoroughly 7 Replace the piston and rings with parts of correct oversize Section 2 4 CRANKSHAFT AND CAMSHAFT GENERAL Prior to removal of the crankcase cover gain access to the engine and generator by removing surrounding sheet metal as required See Section 1 6 CRANKCASE COVER REMOVAL Before attempting to remove the crankcase cover remove rust paint and burrs from the power takeoff PTO end of the crankshaft This will reduce the pos sibility of damaging the oil seal in the crankcase cover or the bearing during cover removal To remove the crankcase cover proceed as follows 1 Drain oil from the crankcase 2 Remove the engine cylinder head push rods and push rod guide plate See Section 2 2 3 Remove all bolts that retain the crankcase cover to the crankcase 4 Remove the crankcase cover If necessary tap lightly with a soft hammer on alternate sides of the cover Figure 1 Crankcase Cover Removal CAMSHAFT REMOVAL See Figure 2 Remove the camshaft as follows 1 Tip the engine over onto the flywheel end of the crankshaft Support the engine to prevent end of crankshaft from resting on the workbench 2 Reach in with two fingers and hold the tappets up so they are clear of the camshaft lobes Then remove the camshaft
127. output will be low A failed stepper motor may also turn erratically If this is the case engine speed and AC output voltage will be erratic under constant load THROTTLE LINK Figure 1 Speed Control System Page 3 6 1 Section 3 6 SPEED CONTROL SYSTEM ELECTRICAL CONNECTIONS BROKEN If one or more of the electrical connections to the stepper motor are broken or disconnected either of the following might occur 1 The stepper motor may not turn at all 2 The stepper motor may turn erratically If the stepper motor does not turn symptoms will be the same as for a failed or seized stepper motor LEADS CONNECTED WRONG Incorrectly connected electrical leads to the stepper motor can result in any one of the following 1 Stepper motor may not turn at all 2 Stepper motor may turn erratically 3 Stepper motor may turn backwards If the stepper motor does not turn engine will start and the following may occur 1 If throttle is open engine will accelerate and shut down when speed reaches 4200 rpm or after 15 seconds due to overvolt age condition 2 If throttle is closed engine will be unable to accelerate under load If the stepper motor turns erratically engine speed and AC output voltage will be erratic under a constant load The AC output will not terminate If the stepper motor is turning backwards engine will accelerate and shut down at 4200 rpm TESTING THE STEPPER MOTOR
128. p or replace spark plug as necessary 2 If spark plug is good but engine will not start go to Test 3 3 If spark plug is good but engine misses or runs rough go to Test 23 TEST 17 CHECK IGNITION POWER SUPPLY DISCUSSION During startup the A6060 circuit board delivers DC power to the Ignition Module via Wire 14 If the engine cranks but won t start one possible cause is loss of this power supply The DC power from the A6060 Circuit Board is deliv ered to a 4 tab terminal connector From that connec tor it is routed to the Ignition Module These components are all housed in the control panel IGNITION MODULE CONNECTOR Figure 9 Ignition Module amp 4 Tab Connector TEST PROCEDURE In the control panel inspect the Wire 14 connections at the 4 tab connector Check Wire 14 Check the power supply as follows 1 Set a VOM to read battery voltage Page 7 2 14 2 Connect the VOM test leads across the 4 tab connector and frame ground 3 Hold the engine Start Stop switch at START The meter should read battery voltage RESULTS 1 If DC voltage is NOT indicated go to Test 21 2 If DC voltage is good go on to Test 18 TEST 18 CHECK IGNITION SENSOR DISCUSSION Refer to Section 6 4 ENGINE IGNITION SYSTEM TEST PROCEDURE See Section 6 4 RESULTS 1 Replace Sensor if bad 2 If Sensor checks good go to Test 19 TEST 19 CHECK IGNITION COIL DISCUSSION See Section 6 4
129. place the A6060 circuit board TEST 13 CHECK FUEL SUPPLY DISCUSSION If the engine cranks but won t start don t overlook the obvious The engine won t start without fuel TEST PROCEDURE Check fuel level RESULTS 1 If fuel level is low replenish fuel supply 2 If fuel quantity is good go to Test 14 TEST 14 CHECK FUEL FILTER Refer to Section 3 3 TEST 15 CHECK IGNITION SPARK Refer to Section 6 4 ENGINE IGNITION SYSTEM TEST 16 CHECK SPARK PLUG DISCUSSION A badly fouled spark plug can prevent the engine from starting A defective spark plug may allow the engine to be started but rough operation or an engine miss may be observed A commercially available spark tester can be used to check for ignition spark When the spark tester is con nected in series with the spark plug and its high ten sion lead the cause of an engine miss can be nar rowed down to either a the ignition system or b the spark plug or fuel system Use of the spark tester is discussed in Test 16 TEST PROCEDURE Remove the spark plug Clean by scraping or wire brushing and by using a commercial solvent DO NOT BLAST CLEAN THE PLUG Set spark plug gap to 0 030 inch 0 76mm Replace spark plug if badly fouled if ceramic is cracked or if damaged Page 7 2 13 Section 7 2 ENGINE DC CONTROL SYSTEM AC TROUBLESHOOTING 0 050 FEELER GAUGE Figure 8 Checking Spark Plug Gap RESULTS 1 Clean and rega
130. r In the computer controlled RV generator generally involve the following systems or components 1 The engine 2 The Speed Control System 3 The AC Generator 4 Battery Charge Circuit 5 A6060 Circuit Board 6 Wiring Harness and Front Panel This Section will discuss test procedures for the fol lowing components Also see Part 8 of this Manual TROUBLESHOOTING 1 The AC Generator Stator 2 Battery Charge Circuit 3 A6060 Circuit Board STATOR ASSEMBLY GENERAL For additional information on the Stator refer to the following 1 Stator Assembly on Page 1 2 2 2 Section 1 4 INSULATION RESISTANCE SYMPTOMS OF STATOR FAILURE If the engine starts but the Stepper Motor does not move and shutdown occurs after several seconds look for broken or shorted timing windings Wires TIM1 and TIM2 TESTING THE STATOR WITH A VOM A Volt Ohm Milliammeter VOM can be used to test the Stator windings for the following faults An open circuit condition A short to ground condition A short circuit between windings NOTE The resistance of Stator windings Is very low Some meters will not read such a low resis tance and will simply Indicate continuity Recommended Is a high quality digital type meter capable of reading very low resistances TESTING POWER PHASE WINDINGS A Refer to Figures 1 and 2 on this page and the next To test the Power Phase windings for an open circuit condition procee
131. r higher soft ware jump pin 10 to pin 11 on the 12 position cable previ ously removed from the inverter The 12 position cable should be connected to the 12 position socket on the generator control panel This will enable the generator to run with CB1 turned ON 3 Turn CB1 to ON position Start generator The engine should run at approximately 3300rpm 4 Set a DVOM to DC volts Measure from the free end of the 12 position harness according to the chart below Connect the negative and positive test leads as indicated in the chart Note Fluke 87 true RMS meter used in test 5 Set a DVOM to AC volts Measure the the free end of the 9 Wire harness according to the chart below Connect the nega tive and positive test leads as indicated in the chart NZ IS Y VER FON ES N N Y JO I AN NW Figure 10 Free End of 12 Position Harness Connect positive lead to Reading should be Inverter Signals Ground Pin 9 0 v Pin 2 En Com lt 0 10 vde Inverter Signal Pin 2 En Com Pin 1 PWM1 2 5 v 0 15 vdc Inverter Signal Pin 2 En Com Pin 3 PWM2 2 5 v 0 15 vdc Temperature Voltage Pin 9 0 v Pin 10 TEMP 5 0 v 0 1 Inverter Fan Voltage Pin 9 0 v Pin 4 Wire 14 12 v 1 0 vdc Shield Wire Test for Ground Pin 12 SHIELD Test With DVOM Set At AC Volts Connect negative lead to Pin 4 Wire 14 12 v 1 0 vdc
132. r seized c Stepper Motor wire connections broken or disconnected d Stepper Motor not properly connected Repair sticking throttle Replace Stepper Motor Reconnect or repair Reconnect wires 2 Overvoltage condition and speed control system cannot reduce output voltage a Carburetor linkage sticking with throttle stuck partly open b Stepper Motor failed or seized c Connection to Stepper Motor is broken disconnected with throttle open d Stepper Motor not properly connected Repair sticking throttle Replace Stepper Motor Repair or replace connections Reconnect Stepper Motor wires 3 Engine speed is maintained and no load voltage is good However when load is applied output voltage drops a Carburetor linkage sticking with throttle partly open b Stepper Motor failed or seized c Connection to Stepper Motor Motor broken or disconnected d Stepper Motor not properly connected Repair sticking throttle Replace Stepper Motor Repair or replace connections Reconnect Stepper Motor 4 Engine does not accelerate when load is applied a Carburetor linkage sticking with throttle stuck closed b Stepper Motor failed or seized c Stepper Motor not properly connected Repair sticking throttle Replace Stepper Motor Reconnect Stepper Motor 5 Engine speed and AC output voltage erratic under constant load AC output does not turn o
133. r to be pulsed The transistor acts much like a switch or a set of con tact points Pulsing the transistor base causes the switch to close and connect the OUT lead to the GND lead This triggers the Ignition Module to deliv er a primary ignition current to the Ignition Coil at timed intervals 12 VDC 100 OHM 20V 1 10W 1 2W 106 OHM 1 10W OUT Figure 3 Ignition Sensor Schematic IGNITION MODULE While cranking and running battery voltage is deliv ered to the Ignition Module via Wire 14 from the A6060 circuit board The Module will deliver this bat tery voltage to the Ignition Coil based on the timing signal it receives from the Ignition Sensor The Ignition Module is retained in the generator con trol panel by two capscrews Page 6 4 1 Section 6 4 ENGINE IGNITION SYSTEM IGNITION MODULE CONTINUED Figure 4 Ignition Module IGNITION COIL Primary ignition voltage 12 VDC is delivered from the Ignition Module to the Ignition Coil The Coil boosts the voltage and delivers the high voltage to the engine Spark Plug 1 Ignition Coil 2 Spark Plug Boot 3 Spark Plug Terminal 4 Snap Bushing Figure 5 Ignition Coil SPARK PLUG The Spark Plug on the GV 220 engine is a Champion RC12YC or equivalent 0 030 FEELER GAUGE 0 76mm Figure 6 Setting Spark Plug Gap Page 6 4 2 Clean the Spark Plug and reset its gap to 0 030 inch 0 76mm every 100 hours of opera
134. re at the carburetor venturi acts on the regulator diaphragm to pull the diaphragm toward the source of low pressure A lever attached to the diaphragm opens a metering valve which allows gas to enter and flow through the carburetor The greater the air flow through the carburetor ven turi the lower the pressure at the venturi throat The lower the pressure at the venturi throat the greater the movement of the diaphragm and the more the metering valve opens AIR GASAT FLOW POSITIVE u ee A N GASAT ZERO PRESSURE LOW PRESSURE AREA Figure 2 Gas Carburetion Diagram The following requirements of the secondary regulator must be emphasized t must be sensitive to pressure changes in the car buretor venturi throughout the entire operating range It must positively stop the flow of gas when the engine is not running The slightest air flow through the carburetor venturi must move the regulator valve off its seat and per mit gas flow LEAKAGE TESTING Whenever any lines fittings or other components of the fuel system have been removed and replaced the system should be carefully checked for leaks before it is placed into service To check for leakage start the engine and let it run Then use a soap and water solution or an approved commercial leak detector solution to determine if any leakage exists No leakage is permitted DANGER DO NOT USE FLAME TO CHECK FOR LEAKAGE GASEOUS FUEL LINE
135. s Lead 2 ii ense 0 414 to 0 465 ohm Lead 55 to 77 0 095 to 0 108 ohm Stator Power Phase Winding Lead 0 095 to 0 108 ohm Lead PST schede 0 206 to 0 227 ohm ENGINE SPEEDS AND VOLTAGE SPECIFICATIONS Listed below are normal running voltages load voltages engine speeds and frequency ranges LOAD VOLTAGE VAC FREQUENCY Hz ENGINE SPEED rpm 0 121 112 61 59 2800 2400 50 120 109 61 59 3500 3000 120 109 61 59 4000 3500 Page 8 1 Part 8 SPECIFICATIONS amp CHARTS ELECTRICAL SCHEMATIC DRAWING NO 0D4947 B 10F2 CUSTOMER SUPPLIED BATTERY 5 Pu ME 13 16 SM 13 NL 7 0 O sw2 14 FP 0 HM C HM REMOTE 15 do LP ONLY EANEE N CONNECTOR cc 14 0 0 0 1004 17 17 2 14 14 17 44 START ER 3 15 14 14 swi o 1 18 4 18 s STOP 15 18 ES z c 14 28565 l 0 0 MM IS 18 14 17 0 15 T HTO L 85 0 eo Ic lt lt LOP 15A BCR 85 l 90 66 77 14 66 BATTERY CHARGE WINDING Tr 56 5 g 18 STARTA 512 511 POWER WINDING AC2 TIMING l WAS POWER SUPPLY l AS 1 17 1 TIM2 5
136. s NOT indicated in Step 6 test Wire 14 RED between the 4 terminal connector and the Ignition Module If wire is bad repair or replace as necessary continued Page 6 4 3 Section 6 4 ENGINE IGNITION SYSTEM TESTING THE SYSTEM CONTINUED CHECK POWER SUPPLY CONTD b If battery voltage is NOT indicated in Step 7 test Wire 14 between the 4 terminal connector and the A6060 circuit board Repair or replace as necessary CHECK IGNITION SENSOR 1 In the 3 pin connector plug half from the Ignition Module locate FEMALE Pin 1 to which the BROWN wire connects 2 Connect a jumper wire from FEMALE Pin 1 BROWN wire to frame ground 3 Connect the Spark Plug high tension lead to a spark tester Figure 8 and the spark tester clamp to ground 4 Crank the engine and observe the spark tester for sparking Note Only one spark should be observed upon initial cranking Figure 12 Testing Ignition Sensor If sparking occurs with the BROWN wire grounded but did NOT occur under TESTING FOR SPARK the Ignition Sensor is probably defective and should be replaced NOTE The Ignition Sensor is mounted to the gen erator s Stator Adapter To replace the Sensor disassembly of the generator and removal of the Stator will be necessary If sparking does NOT occur with the BROWN wire grounded and did NOT occur under TESTING FOR SPARK either the Ignition Module or the Ignition Coil is defective Go to TESTING IGNITION
137. s Wire 13 RED from the Starter Contactor to the 15 amp Fuse It includes one Wire 15 from the Fuse to the Primer Switch and a Wire 15 from the Fuse to the A6060 cir cuit board TEST PROCEDURE Inspect the battery terminals and cables carefully Clean cables and cable connections if necessary Replace any bad cable s including the battery nega tive cable if necessary Check Wires 13 and 15 for an open or shorted condition Repair reconnect or replace bad wire s as necessary Use a battery hydrometer to test the battery for state of charge and for condition Follow the hydrometer manufacturer s instructions carefully If the hydrome ter used does not have a percentage of charge scale use the following as a reference SPECIFIC GRAVITY PERCENTAGE OF CHARGE 1 260 10076 1 230 7596 1 200 50 1 170 25 RESULTS 1 Repair reconnect or replace any open or shorted wi re s 2 If necessary recharge the battery to a 100 state of charge Disconnect the battery cables before recharging the battery 3 If after recharging the difference in specific gravity between the highest and lowest reading cells is greater than 0 050 50 points the battery is nearing the end of its useful life and should be replaced TEST 5 TEST FUEL PUMP Refer to Page 3 3 1 TEST 6 TEST PRIMER SWITCH DISCUSSION See Figure 2 on facing page When this rocker type switch is held at PRIME position fused battery volt
138. s toward the cage outer periphery A special fixture is used to install the cage onto the rotor hub so that the center line of the first magnet is 68 away from the Rotor Hub mounting hole as shown NOTE Placement of the magnets on the Rotor Hub at the exact position stated above results in an ignition timing of 29 BTDC The Ignition Cage assembly cannot be replaced The entire Rotor Hub must be replaced Replacement Rotor Hubs will include a factory installed Ignition Cage assembly and Magnetic Housing Assembly NOTE Also refer to Permanent Magnet Rotor in Section 1 2 Page 1 2 1 ROTOR IGNITION CAGE pinus Ras a qu _ r ESOO ES y PIT N N Figure 1 Ignition Cage Assembly IGNITION SENSOR The Ignition Sensor is retained to the AC generator s Stator Adapter by means of two M4 0 70 x 8mm screws and lockwashers The Sensor housing houses a circuit board The entire housing cavity is filled with potting material As the generator s Permanent Magnet Rotor turns during operation magnets on the Ignition Cage rotate past the Ignition Sensor to induce a timed low voltage pulse into the Sensor This voltage pulse is delivered to an Ignition Module and serves as a timing pulse for the Module Figure 2 Ignition Sensor See Figure 3 The Sensor circuit board mounts solid state components which are sensitive to magnetism Magnets in the Ignition Cage rotate past the Sensor causing the base of a transisto
139. t be explained by our present knowledge However there are certain pat terns of behavior that are known Application of these behavior patterns has led to the development of gen erators motors and numerous other devices that uti lize magnetism to produce and use electrical energy See Figure 1 The space surrounding a magnet is permeated by magnetic lines of force called flux These lines of force are concentrated at the magnet s north and south poles They are directed away from the magnet at its north pole travel in a loop and re enter the magnet at its south pole The lines of force form definite patterns which vary in intensity depend ing on the strength of the magnet The lines of force never cross one another The area surrounding a magnet in which its lines of force are effective is called a magnetic field Like poles of a magnet repel each other while unlike poles attract each other Magnetic Lines of Force Figure 1 Magnetic Lines of Force ELECTROMAGNETIC FIELDS All conductors through which an electric current Is flowing have a magnetic field surrounding them This field is always at right angles to the conductor If a compass is placed near the conductor the compass needle will move to a right angle with the conductor The following rules apply The greater the current flow through the conductor the stronger the magnetic field around the conductor The increase in the number of lines of force is dir
140. ted for both STATE OF CHARGE and CONDITION as follows 1 Test for State of Charge a Follow the hydrometer manufacturer s instruc tions carefully Test the specific gravity of the fluid in all battery cells b If the hydrometer does not have a Percentage of Charge scale compare the readings obtained with the following SPECIFIC GRAVITY PERCENTAGE OF CHARGE 1 260 10076 1 230 75 1 200 50 1 170 25 If the battery State of Charge is less than 100 use an automotive type battery charger to recharge itto a 100 State of Charge 2 Test for Condition a lf the difference in specific gravity between the highest and lowest reading cell is greater than 0 050 50 points the battery is nearing the end of its useful life and should be replaced b However if the highest reading cell is less than 1 230 recharge the battery and repeat the test START RUN STOP SWITCH SW1 Wires 17 and 18 connect to the two outer terminals of the switch Wire O ground connects to the switch center termi nal The switch can be tested using a volt ohm milliamme ter VOM as follows Figure 2 Page 6 3 2 1 Set the VOM to its Rx1 scale and zero the meter 2 Connect the VOM test leads across the Wire 17 terminal and the center Wire 0 terminals a Hold the switch at START and the VOM should indicate continuity b Hold switch at STOP and meter should read infinity 3 Now connect the meter test le
141. terminate generator AC output THROTTLE LINKAGE ADJUSTMENT If necessary the length of the linkage between the Stepper motor and the carburetor throttle lever arm can be adjusted This adjustment helps to establish the proper travel relationship of the linkage If the adjustment is not correct the A6060 board will not be able to control the full range of engine speed The fol lowing conditions might occur e f the throttle linkage is set too short the system will not be able to provide wide open throttle or full power conditions e f the linkage is set too long the system will not be able to provide closed throttle or no power condi tions Use the following procedure to ensure the linkage rod is properly adjusted 1 Start the engine and immediately shut it down As the engine coasts to a stop observe from above the engine as the carbu retor throttle lever rotates counterclockwise 2 There should be a gap of about 0 003 inch 0 08 0 5mm between the stop tab on the throttle lever arm and the stop block on the carburetor casting See Figure 4 CAUTION The next step involves bending a spring clip Do NOT overbend the clip or it may lose its clamping force 3 Use pliers to lightly compress the spring clip on the carburetor lever arm Figure 5 This permits the linkage rod to slide freely through the clip With the clip compressed rotate the throttle lever in the appropriate direction until there is a 0 003 inch 0 08
142. test Figure 2 The Stepper Motor Connector Pictorial Schematic Figure 3 The Stepper Motor PART 4 GASEOUS FUEL SYSTEM COMPUTER CONTROLLED VARIABLE SPEED RV GENERATORS Series Impact 36 Plus SECTION TITLE 4 1 INTRODUCTION TO FUEL SYSTEM 4 2 SHUTOFF VALVE amp REGULATOR 4 3 CARBURETOR NOTE Information on the following is the same as for the GASOLINE FUEL SYSTEM Part 3 Air Cleaner amp Air Intake Section 3 2 Speed Control System Section 3 6 NOTES Section 4 1 INTRODUCTION TO FUEL SYSTEM GENERAL INFORMATION Some RV generator models are equipped with fuel systems that utilize LP gas as a fuel The initials LP stand for liquefied petroleum This gas is highly volatile and can be dangerous if handled or stored carelessly All applicable laws codes and regulations pertaining to the storage and handling of LP gas must be com plied with The installation of such fuel systems must also be in compliance with such laws codes and reg ulations Service technicians who work on these sys tems must do nothing that might cause the system to be in non compliance with regulations Regulations established by the Recreational Vehicle Industry Association RVIA must be followed in the installation use and servicing of such systems DANGER LP GAS IS HIGHLY EXPLOSIVE THE GAS IS HEAVIER THAN AIR AND TENDS TO SETTLE IN LOW AREAS EVEN THE LIGHTEST SPARK CAN IGNITE THE GAS AND CA
143. the A6060 circuit board Figure 10 Receptacle J2 TEST 22 TEST AUTOMATIC CHOKE DISCUSSION Refer to Section 3 5 AUTOMATIC CHOKE TEST PROCEDURE See Section 3 5 RESULTS 1 Adjust or repair choke system as necessary 2 If choke is good go to Test 23 TEST 23 CHECK CARBURETION DISCUSSION If the engine won t start or if it starts hard and runs rough one possible cause of the problem is carburetion PROCEDURE Before making a carburetion check make sure the fuel tank has an ample supply of clean fresh gasoline gasoline fuel systems or gaseous fuel The installer may have installed a gas or gasoline shutoff valve in the fuel supply system Make sure all shutoff valves are open Make sure the automatic choke is working properly and that the choke closes completely If the engine will not start remove the spark plug and inspect it If the plug is WET look for the following Overchoking Water in fuel Excessively rich fuel mixture ntake valve stuck open If the spark plug is DRY look for the following Carburetor gasket s leaking Fuel line plugged or shutoff valve not opening e Intake valve stuck closed noperative fuel pump Clogged fuel filter RESULTS Adjust or repair carburetor or fuel system as necessary TEST 24 CHECK ENGINE DISCUSSION An engine that will not start or one that starts hard
144. tion Clean by scraping or wire brushing and washing with commer cial solvent DO NOT blast clean the spark plug SUMMARY OF OPERATION See Figure 6 As the generators permanent magnet rotor turns magnets in the Rotor hub s Ignition Cage rotate past an Ignition Sensor at fixed intervals Battery voltage is delivered to an Ignition Module dur ing cranking and running via Wire 14 From the Ignition Module battery voltage is also delivered to the Ignition Sensor via the RED lead The Ignition Sensor acts as a trigger mechanism causing the Ignition Module to deliver its output to the Ignition Coil at timed intervals Current flows through the primary coil of the Ignition Coil and then collapses to induce a high voltage into the Ignition Coil s secondary coil This high voltage about 25 000 volts is delivered to the park Plug to fire the spark plug gap Components encapsulated in the Ignition Module pro vide an automatic spark advance At cranking speeds ignition will occur at about 15 18 BTDC At higher speeds ignition can occur up to 29 BTDC oc IGNITION MODULE Figure 7 Ignition System Diagram IGNITION TIMING Ignition timing is fixed and non adjustable TESTING THE SYSTEM GENERAL Solid state components inside the Ignition Sensor Ignition Module and Ignition Coil are not accessible and cannot be serviced If any of these components is defective the entire component must be replaced The system does
145. to frame ground Engine shutdown will then occur HIGH OIL TEMP SWITCH LOW OIL PRESSURE SWITCH A6060 A Schematic B Wiring Diagram Figure 1 Engine Protective Circuit LOW OIL PRESS SWIT Figure 2 Engine Protective Devices Figure 3 Testing the Oil Temperature Switch TESTING See Figure 3 Remove the switch and place its sens ing tip into oil Place a thermometer Into the oil Connect the test leads of a VOM across the switch terminals The meter should read Infinity Heat the oil When oil temperature reaches approximately 287 296 F 142 147 C the meter should read continuity a small resistance is acceptable continued Page 6 5 1 Section 6 5 SHUTDOWN FEATURES ADDITIONAL SHUTDOWN FEATURES The A6060 Circuit Board also incorporates the follow ing protective shutdown features LOSS OF 12 PIN CABLE SIGNALS TO INVERTER The generator will shutdown if the 12 pin connector is disconnected from the inverter when CB1 is turned to ON This shutdown will occur after approximately 5 7 seconds LOSS OF TIM1 TIM2 INPUT TO A6060 CIRCUIT BOARD If Timing Winding input is lost the generator will immediately shutdown LOSS OF PS1 PS2 TO INVERTER A loss of voltage from PS1 PS2 windings to the inverter will simulate a 12 pin signal failure and cause a shutdown when CB1 is turned to ON This shutdown will occur after approximately 5 7 seconds OVERSPEED OF ENGINE Overspee
146. ts are on the circuit In such a case current will be in phase with voltage that is the cur rent sine wave will coincide in time with the voltage sine wave However two factors in AC circuits called INDUC TIVE and CAPACITIVE REACTANCE will prevent the voltage and current sine waves from being in phase INDUCTIVE REACTANCE This condition exists when current lags behind volt age Figure 8 As current flows in a circuit magnetic lines of force are created at right angles to the con ductor The continuous changes in current value from positive to negative cause these magnetic lines to collapse and build up continuously The magnetic field around the conductor induces electromotive forces that cause current to keep on flowing while voltage drops The result is a condition in which voltage leads current When a conductor is formed into a coil the magnetic lines of force are con centrated in the center of the coil This increased den sity causes an increase in magnetically Induced EMF without increasing current Thus coils cause inductive reactance Inductive reactance can also be caused by placing an induction motor on the circuit which utilizes the cur rent s magnetic field for excitation Current T fi Current Lags Vol Gie Figure 8 Inductive Reactance Page 1 1 3 Section 1 1 GENERATOR FUNDAMENTALS CAPACITIVE REACTANCE This condition occurs when current leads voltage Figure 9 It might be
147. uel primer switch on the generator panel to its ON position a The meter should indicate battery voltage b The solenoid should energize open RESULTS OF TEST 1 If battery voltage is Indicated but the solenoid does NOT ener gize replace the lockoff solenoid 2 If battery voltage is NOT Indicated a problem exists In the DC control system See Parts 6 ENGINE ELECTRICAL SYS 4 2 2 Figure 3 Fuel Lockoff Solenoid Section 4 3 CARBURETOR GENERAL DISASSEMBLY AND REASSEMBLY The carburetor is designed for use with LP gas in its The carburetor is replaced as an entire assembly vapor form The following specifications apply Disassembly and reassembly is not required Carburetor Inlet Diameter 1 02inch 26mm Carburetor Outlet Diameter 0 78 inch 20mm Venturi Diameter 0 63 inch 16mm Main Jet Diameter Number 370 Measured Size 0 145 inch 3 7mm CARBURETION Refer to Gaseous Carburetion in Section 4 1 Page 4 1 3 CARBURETOR ADJUSTMENT The LP gas carburetor used on Impact Plus generator sets is equipped with a fixed jet and is non adjustable CARBURETOR REMOVAL Refer to Part 3 Section 3 4 Page 3 4 3 for carburetor removal procedures Figure 1 LP Gas Carburetor Page 4 3 1 Section 4 3 CARBURETOR Page 4 3 2 5 ENGINE OIL amp COOLING SYSTEM ENGINE OIL SYSTEM ENGINE COOLING S
148. ug connects to the A6060 This harness then connects to a 9 pin connector plug on the outside panel of the control box This becomes the 9 wire harness that connects to the inverter Signals from the A6060 circuit board control the func tions of the inverter RECEPTACLE J2 The A6060 circuit board mounts a 10 pin receptacle J2 A 10 pin connector plug connects to this recepta cle to interconnect the board with other components and circuits This 10 pin receptacle is shown in Figure 2 along with a chart that Identifies each pin wire and function Wire 14 connects to Terminal J2 9 This terminal and wire are electrically hot 12 volts DC only when the engine is cranking or running Battery voltage is deliv ered to Terminal J2 9 when circuit board action ener gizes a board mounted run relay while cranking or running Wire 14 DC output is delivered to a the engine fuel pump and b the engine ignition system If an option al remote panel Is used Wire 14 DC output will turn on a RUN lamp on that panel Wire 15 connects to Terminal J2 5 This Is fused bat tery voltage The Wire 15 circuit is electrically hot at all times provided the unit battery Is connected Figure 2 Receptacle J2 PIN WIRE FUNCTION 1 Not Used 2 18 3 85 When grounded by Low Oil Pressure or High Oil Temperature Switch the circuit b
149. uired to compress the spring to a length of 1 39 inch 35 2 mm Replace any damaged or defective spring INTAKE EXHAUST BE SURE TO LUBRICATE VALVE GUIDES amp STEMSI Figure 11 Installation of Intake and Exhaust Valves Page 2 2 3 Section 2 2 VALVE TRAIN VALVE COMPONENTS INSTALLATION CONTINUED 3 Install the valve spring washers valve springs and valve spring retainers over the valve guides a Hold the valve with your fingers and use your thumbs to compress the spring b When the spring is compressed sufficiently slide the spring retainer small opening over the valve stem c With the smaller retainer opening around the valve stem release the spring Figure 12 Installing Valve Spring Washers 4 After both valves have been retained in the cylinder head posi tion a new head gasket and install the cylinder head NOTE The head gasket is coated with a special substance for beer sealing The gasket must be free of nicks scratches and other defects for bet ter sealing 5 Install cylinder head bolts Tighten the head bolts in the sequence shown to the recommended tightness TIGHTENING TORQUE CYLINDER HEAD GV 220 29 foot pounds TORQUE SEQUENCE 1 2 3 4 5 Figure 13 Head Bolts Tightening Sequence Page 2 2 4 6 Place the push rod guide plate into position on the head Then install the rocker arm and the pivot ball stud The rocker arm jam nut must be on far enough to hold the
150. ular protrusion Clean the screen in solvent then inspect for damage Replace the screen if necessary OIL PUMP DESCRIPTION The oil pump is of the trochoid type Its inner rotor rotates on a shaft provided in the camshaft bore of the oil sump The outer rotor is installed over two drive pins on the end of the camshaft and is driven by camshaft rotation TO CRANKCASE INNER COVER Figure 2 Oil Pump INSPECTION See Figure 3 Inspect the inner and outer rotors of the pump for damage and wear Use a feeler gauge to check tip clearance of the rotor measured on the shaft in the oil sump Check the bore inner diameter and the thickness of the inner rotor If wear limits are exceeded replace the appropriate part s PUMP TIP CLEARANCE MEASURED ON SHAFT IN OIL SUMP DESIGN CLEARANCE 0 0000 0 0010 inch 0 000 0 025mm WEAR LIMIT 0 004 inch 0 105mm Maximum INNER PUMP ROTOR BORE DESIGN BORE 0 354 0 355 inch 9 000 9 019mm WEAR LIMIT 0 357 inch 9 034mm Maximum INNER ROTOR THICKNESS DESIGN THICKNESS 0 312 0 315 inch 7 95 8 00mm WEAR LIMIT 0 311 inch 7 90mm Minimum Replace any part that is damaged or worn excessive ly The shaft on which the inner rotor rotates is NOT replaceable oil sump must be replaced Page 5 1 1 Section 5 1 ENGINE OIL SYSTEM OIL PUMP CONTINUED PRESSURE RELIEF VALVE INSPECTION CONTD DESCRIPTION Inspect the outer drive pins on the camshaft Loo
151. voltage should be approximately 375 VDC Measure DC link voltage between the Red wire and Black wire place Red test lead to Red wire and Black test lead to Black wire DC voltage should read 175 VDC Measure DC link voltage between the Blue wire and the Black wire place Red test lead to Blue wire and Black test lead to Black wire DC voltage should read 175 VDC Section 7 2 ENGINE DC CONTROL SYSTEM AC TROUBLESHOOTING TEST 29 12 POSITION HARNESS CONTINUITY TEST 1 Set VOM to measure Resistance 2 Measure from pin location 1 on one end of the 12 position harness to pin location 1 on the opposite end of the harness A reading of Continuity should be measured Repeat proce dure for each pin position on the 12 wire harness If an open condition is detected replace the defective harness as neces sary 3 If needed check for continuity on the A6060 circuit board wire harness in the control panel This connection is at location J1 on the circuit board Follow the same procedure as steps 1 and 2 above TEST 30 12 POSITION HARNESS SIGNALS TEST ASSUMPTION Engine runs Inverter not connected TEST PROCEDURE 1 Disconnect the 12 wire cable from the inverter Disconnect the Red Black Blue Green DC Link wires from the inverter Note Cap the DC Link wires with a wire nut for safely Test With DVOM Set At DC Volts Connect negative lead to 2 On units with A6060 circuit board revision o
152. w PAPER FILTER Into COVER 5 Install COVER with PAPER FILTER Retain to BASE with two Screws AIR INTAKE See Figure 2 Air is drawn into the air cleaner passes through the air cleaner filter and is then ported to the carburetor air inlet through an air intake hose Periodically inspect the air intake hose for condition damage holes perforations etc Replace hose if necessary Inspect air intake hose clamps for tight ness condition Tighten or replace as necessary Figure 2 Air Intake Components Page 3 2 1 Section 3 2 AIR CLEANER AND INTAKE Page 3 2 2 Section 3 3 FUEL FILTER AND FUEL PUMP FUEL FILTER The fuel filter should be removed and replaced every 100 hours of operation or once each year whichever occurs first Fuel Filter Customer Fuel Connection 7 Figure 1 Fuel Filter Typical FUEL PUMP DESCRIPTION The 12 volts DC electric fuel pump has a zinc plate finish Flow through the pump is positively shut off when It is not operating The pump is actually rated at a voltage of 8 to 16 VDC but has a nominal voltage rating of 12 VDC Current draw of the pump at nominal voltage is approximately 1 4 amperes maximum Pressure rating of the pump at zero delivery is 2 0 to 3 5 psi Two wires are brought out from the pump The black wire Is grounded by connecting it to a pump mounting bolt The red wire Is identified as Wire No 14A The pump will operate whenever The FUEL PRIME
153. wo screw holes in the COVER are slotted to provide for axial adjustment of the CHOKE SOLENOID A COTTER PIN retains a CHOKE LINK to the SOLENOID A CHOKE BI METAL amp HEATER is retained to the SOLENOID by two No 4 40 SCREWS LOCKWASH ERS and FLATWASHERS FASTENERS Bl METAL 4 HEATER ASSEMBLY j COTTER PIN Figure 1 Choke Solenoid Parts OPERATION NOTE Also see Part 6 ENGINE ELECTRICAL SYSTEM The section on DC control system includes additional information on choke opera tion and the A6060 circuit board When the engine is being cranked A6060 circuit board action energizes the choke solenoid in regular timed cycles Each time the choke solenoid is ener gized it closes the carburetor choke valve The circuit board s choke timer circuit energizes the choke sole noid pulls it in about every 2 to 5 seconds When the engine starts cranking is terminated The choke action is then terminated and the choke setting is determined by a choke heater CH OPERATIONAL CHECK AND ADJUSTMENT OPERATIONAL CHECK Crank the engine During cranking the choke sole noid should pull in about every 2 to 5 seconds If it does NOT pull in try adjusting the choke PRE CHOKE ADJUSTMENT With the solenoid NOT pulled in the carburetor choke valve choke plate should be about 1 8 inch from its full open position If necessary use needle nose pli ers to bend the tip of the BI METAL until a 1 8 inch setting is obtained CH

Generac Power Systems 940-2 Portable Generator User Manual

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